1 Preface 2 General Instructions 2.1 Application range 2.2 Warnings contained in the operating instruction 2.3 Notes on deliveries 2.4 Transport and storage 2.5 Warranty notes 2.6 Notes on return deliveries 3 Safety 3.1 Proper use 3.2 Qualifi ed personnel 4 Technical description 4.1 Components of the measuring device 4.2 Mode of functioning of the Corrosion Detector Portable 4.3 Properties of the measuring device 4.6 Application limits 4.7 Menu structure 4.8 Operating concept 4.9 Starting up 4.10 Measurement 5 Replacing the batteries 6 Technical data of the Corrosion Detector Portable 7 Note Operating Instructions 338-1 e
1 Preface The present Operating Instructions are designed to familiarize users with the equipment of the Corrosion Detector Portable and its use. The operating instructions (OI) should be accessible to the operating and maintenance personnel in order to ensure that all necessary information is available for using the device. By knowing these OI, you can avoid damage to the measuring equipment and prevent incorrect operation. The information contained in the operating instructions corresponds to the state of the art at the time it is printed and is provided to the best of our knowledge. We reserve the right to include any improvements, amendments and new developments in the operating instructions without prior notice. The actual design of products may differ from the information provided in the catalog if warranted by technical modifi - cations resulting from product improvements. The proposal submitted by Pfaudler for a concrete application will be binding in this case. The latest edition will always supersede all previous ones. The present operating instructions are made available to our customers and interested parties free of charge. Reprints and copies as well as transformation into electronic forms, in whole or in part, shall require our written approval. All rights reserved. 2 General instructions 2.1 Application range The Corrosion Detector Portable is used to inspect glass lined vessels and their internal parts for damages and the resulting metal corrosion. Reactors and internal parts with other insulating coatings (e.g., plastic material or rubber) may also be checked for corrosion of metals using this device. 2.2 Warnings contained in the operating instructions In the operating instructions, the danger symbol is used to draw your attention to especially important safety instructions. Compliance with these instructions is mandatory, because adherence to the instructions can avoid serious mistakes. 2.3 Notes on deliveries The respective scope of delivery is specifi ed on the shipping documents attached to the shipment and corresponds to the valid purchase agreement. Check that the items delivered are complete and intact. 2.4 Transport and storage The Corrosion Detector Portable should be exclusively transported and stored in its closed original case. In order to ensure an as-new condition of the device and accessories, the following storage conditions should be maintained: dry and dust-free steady temperature and ventilation 2.5 Warranty notes Any warranty claims shall not be extended or limited by the information contained in the present operating instructions. For the exact warranty conditions, please refer to the Terms of Sale of Pfaudler Werke GmbH as amended. All warranty claims will be void if the unit is opened. 2.6 Notes on return deliveries Before sending used immersion probes to Pfaudler Werke GmbH or third parties for repair or other purposes, all parts must be cleaned and decontaminated. To protect our staff and for insurance reasons, your return shipment must be accompanied by a clearance certifi cate on which you confi rm that the immersion probes were properly cleaned and decontaminated. You may obtain a form sheet for this purpose from us on request. 2 Pfaudler Werke GmbH
3 Safety For detailed safety instructions and information concerning explosion protection, please refer to the end of the operating instructions. 3.1 Proper use Any use of the equipment for purposes other than described in the present operating instructions will adversely affect the safety and functioning of the measuring device and is therefore not allowed. It is important to note the safety instructions applicable to the electrical systems and equipment and all explosion protection provisions, if any. 3.2 Qualifi ed personnel The unit may only be operated by authorized technical personnel in strict compliance with the present operating instructions as well as the valid standards and provisions. The failure to observe these instructions no matter whether intentionally or negligently releases Pfaudler Werke GmbH from all liability and warranty claims. 4 Technical description 4.1 Components of the measuring device Check the items delivered for completeness. The following items are included in the delivery: Hard-sided case with molded insert taking up the measuring device Corrosion Detector Portable including batteries Immersion probe and reference electrode Grounding clamp with contact monitoring Reference electrode (spare) File for cleaning contacts Operating Instructions 4.2 Mode of functioning of the Corrosion Detector Portable If metal gets in contact with a conductive liquid (electrolyte), the result is a voltaic cell. That means that a voltage is generated at the contact surface between the metal and the electrolyte. The value of the voltage is subject to the type of the metal and the chemical properties of the electrolyte. If the voltage exceeds a certain value, metal ions are dissolved, i.e. the metal is corroded. In other words, the metal is decomposed. The voltage value as of which a certain metal is decomposed (corroded) is referred to as the decomposition voltage. Since the corrosion resistance depends on the type of metal, the decomposition voltage also differs between metals. As a result, each metal is characterized by its own specifi c decomposition process (corrosion) which can be electrically distinguished from that of other metals. The measuring device with the Corrosion Detector Portable as the central element works with AC voltage, thus avoiding electrochemical reactions at the measuring electrodes. The measuring loop consists of 4 electrodes the 2 measuring electrodes, the reference electrode and the reactor wall as the 4 th electrode. Pfaudler Werke GmbH 3
4.3 Properties of the measuring device The device works according to the principle of impedance analysis. That means: The Corrosion Detector Portable will output an alarm only if metal corrosion has actually occurred on the reactor or the internal parts. Compared to conventional glass monitoring equipment which works according to the principle of conductivity analysis, this method offers fundamental advantages. Conventional systems are not capable of distinguishing between a real alarm and a false alarm when an alarm is signaled. A real alarm is present if the coat is strongly damaged, resulting in a conductive link between the product and the metal (and thus the equipotential bonding system). Such a damage will always be accompanied by corrosion in the damaged spot. A false alarm is defi ned as a conductive link between the product and the equipotential bonding system that is not caused by glass damage. Such links to other plant sections not resistant to corrosion may be the result of production-specifi c operating conditions, e.g., condensate bridges built up via the reactor s nozzles, or when fi lling or draining the reactor. Conductive plant components made of tantalum, titanium, Hastelloy C4, graphite, conductive gaskets or repair plugs made of noble metals do not trigger off a corrosion alarm. 4.4 Construction of the immersion probe The body of the immersion probe is made of PTFE, the highly fl exible, shielded cable with a length of 10 m is insulated with an acid-resistant silicone coat. In the upper part of the probe, the two corrosion-resistant measuring electrodes have been arranged at a 180 offset. The exchangeable reference electrode has been screwed into the lower part, which is closed by a bulgy PTFE plug that prevents contact between the reference electrode made of steel and the glass. Resistors have been integrated into the immersion probe that enable the unit to check whether contact has been made with all electrodes through the cable prior to each measurement as soon as the probe is connected. 4.5 Function of the grounding clamp The grounding clamp is connected to the device through a silicone-insulated cable 3 m in length. Special stainless steel contacts have been integrated into the clamp which enable the unit to monitor the cable and the positive contact with the reactor or potential bonding system. 4.6 Application limits Inappropriate products Solvents, acetic acid, products or water with insuffi cient conductivity. Aggressive media with insuffi cient conductivity, such as bromine or hydrogen bromide. Chemical resistance of the immersion probe The silicone cable and the measuring electrodes are not suitable for permanent use, however, they are resistant to corrosion during short measurements in acids at room temperature. The exchangeable reference electrode is not resistant to corrosion, therefore, it is subject to varying degrees of attack, depending on the acid. If erosion has reached the O-ring seal, the reference electrode must be renewed. 4 Pfaudler Werke GmbH
4.7 Menu structure Initial start-up ON Start-up ON Select language Date/Time Owner Corrosion Detector Menu User Test Conductivity calc. Archive Setup Select user New record Edit User name Company:. Name:... Select test location New record Edit location Company:... Bldg: Reactor:.. Prepare measurement Grounding clamp: connect Immersion probe: connect Conductivity calc. Calculate conductivity of approx. 1 ms Conductivity calculator Material : HCL 37% Reactor vol.: 1.0m³ Required 1.08 kg quantity: 0.72L Measurements archive Select measurement Entry XYZ Company/Bldg./Reactor Date/Time Measured result Note Setup System status Set time Language selection LCD contrast Owner Corrosion limit Select Prepare measurement Grounding clamp: Immersion probe: Test Prepare test Grounding clamp: Immersion probe: Conductivity too low HCL (hydrochloric acid) H2SO4 (sulphuric acid) CH2O2 (formic acid) NaCl (common salt) KCL (potassium chloride) Status Firmware:. Battery:... mv... % Wait short time until electrodes have been reconditioned, then repeat measurement Test running 300 sec remaining Test not possible - Add acid Test finished No corrosion Save test? No Yes Archive Test running Aborted Test finished Save test? Yes No Test finished Locate spot? No Yes Add salt and/or acid Press 0 key to turn the OE and KW measured values on or off Status Memory allocation User:... Locations:.. Measured data:... Set time Date: Time Select language German English LCD contrast + / - Locate spot 44 sec No corrosion Finished Locate spot 44 sec Finished Enter owner Text:.. Corrosion limit Factory setting -20 Range: 0 to -160mV Figure 1 Corrosion Detector Portable Pfaudler Werke GmbH 5
4.8 Operating concept The relevant softkey function is shown on the display Press to select menu items or to confi rm inputs Delete key for input errors Press arrow or cursor keys to move the cursor is used to abort an activity or to return to the main menu step by step Immersion probe (red) The sockets and connectors are marked by different colors Figure 2 Connection and Keyboard Grounding clamp (green) 4.9 Starting up When starting up the unit for the fi rst time, you are requested to enter the language, date/time and the new owner, e.g. Pfaudler (refer to 4.9.5, Owner). (The owner s name can be changed whenever necessary in the SETUP menu) 4.10 Measurement 4.10.1 User: The user may enter his name in the main menu, a max. of 50 users are possible. This entry is made once, whenever the unit is used again, the relevant user may select his name from the list. Corrosion Detector User:.dler/Tabert Test Conductivity calculator Archive Setup 29.06.07 08:00:00 Press ON to turn the unit on or activate the display's light Press 0 to display measured values or to insert a blank when making entries 4.10.2 Test: Do not select Test unless the reactor is ready for the measurement. The Select test location menu is displayed. Select New record if no measurements have been stored in the archive yet. If a reactor has been tested before, it may be selected, and a new record and index no. is generated by pressing Copy. Select test location <New record> Chemical\G22\R12345 Chemical\G22\R12361 Pfaudler\G98\R12379 Pfaudler\G99\R9988 Copy Edit Corrosion Detector I = 444 µa f = 10 Hz OE = 265 mv d = 350 KW = 616 mv UBAT = 4236 mv 18:19:20 Keys for entering numbers or letters Press OFF to turn the unit off When New record has been selected, the Edit location window appears where the company, building and reactor names can be entered, for example. The Reactor line is mandatory. Edit location Company: Chemical Bldg: G22 Reactor: R12345 A/a ABC A/1 Up to 500 locations can be stored. 6 Pfaudler Werke GmbH
Once this data has been entered and confi rmed, you will be requested to connect the grounding clamp and the immersion probe. Prepare measurement Chemical\G22\R12345 Grounding clamp: CONNECT!! Immersion probe: CONNECT!! Connect the grounding clamp to the equipotential bonding system or a bare conductor at the reactor; will be displayed if the clamp has been properly connected. Immerse the probe down to the bottom of the reactor. Attention! Previously turn off the agitator. Start measurement. Prepare measurement Chemical\G22\R12345 Grounding clamp: Immersion probe: MEASURE When the measurement has been started, the system checks whether the conductivity and the acid value of the reactor contents or the product are suffi cient for the measurement. If the corrosion potential is too low, the message Test not possible Add acid will be displayed after a short while. Add the OE and KW measured values by pressing the 0 key. Test running When the display appears green, the message Test fi nished, No corrosion. will be displayed. Select No to repeat the measurement and restart the process, or save the values by hitting Yes. Test fi nished No corrosion Save test? No 300 s remaining OE = 265 mv KW = 616 mv Cancel Yes Up to 10,000 measurements can be stored (circulating). When the display appears red, the message Test fi nished,. will be displayed. Select No to repeat the measurement and restart the process, or save the values by hitting Yes. Test fi nished Save test? No Test fi nished Locate spot? No Yes After saving, the display will show Locate spot? You now have the opportunity to locate the corroded spot inside the reactor. If Yes is selected, the display starts fl ashing. Locate spot Yes Empty the reactor in batches; there is no longer any contact if the display fl ashes green. Attention! Make sure that the immersion probe does not get stuck in the bottom valve. 44 s Finished Pfaudler Werke GmbH 7
4.10.3 Conductivity calculator If water is used for testing the reactor, the conductivity or acid value fi rst has to be set to approx. 1 ms in order to obtain a reliable measurement. 4.10.4 Archive All measurements are stored in the archive. When the measurement has been completed, additional information can be input under Note. 4.10.5 Setup The following settings and controls can be entered in the Setup menu. Setup Conductivity calculator Calculate conductivity of approx. 1mS Measurements archive 03.04 12:34 <> 03.04 11:11 <Corros.> 03.04 10:00 <Corros.> 02.04 09:22 Text 29.03 12:34 <Corros.> System status Set time Language selection LCD contrast Owner 08:00:00 Setup The most common acids and salts have been stored under the Materials option of the calculator. For the acids, you can set a percentage and then enter the reactor volume in m 3. The necessary quantity is indicated in kilos, and additionally in liters for the acid. Conductivity calculator Material: HCl 37 % Reactor vol: 1.0 m3 Select desired measurement and make the desired entries using the Edit option of the Note menu. Entry 1/19 Chemical\G22\R12345 03.04.07 11:11:11 <Note> Edit Set time Language selection LCD contrast Owner Corrosion limit 08:00:00 Required quantity: 1.08 kg 0.72 L Entry 1/19 Chemical\G22\R12345 03.04.07 11:11:11 Damage in bottom area Edit Only the measurements performed by the active user will be displayed in the archive. 8 Pfaudler Werke GmbH
System status: Software version, battery voltage display, capacity and memory allocation. Status Firmware: 1.0.10 Batterie: 4319 mv 81% Language selection: Currently, German and English are available. Language selection Deutsch English Français Italiano Español Corrosion limit: The factory setting is 20 mv, and 0 mv would be even more sensitive. If materials are used that are characterized by slight corrosion under normal conditions already, the sensitivity can be reduced to 160 mv in several steps. Corrosion limit Status Memory allocation: User: 3 of 50 Locations: 35 of 500 Meas. results: 52 of 10000 (circulating) Set time: Date and time input. LCD contrast: Individual contrast setting adjustment. LCD contrast >>> +2 <<< >>> +1 <<< >>> 0 <<< >>> 1 <<< >>> 2 <<< Default 0 mv 20 mv 40 mv 60 mv Default If the alarm threshold is changed, the proper functioning of the unit should be verifi ed by simulating a damage. Set time Owner: A new name can be entered here if the owner changes. 29.06.07 08:00:00 Enter owner tt.mm Text A/a ABC A/1 Pfaudler Werke GmbH 9
5 Replacing the batteries Open the battery compartment on the back of the unit and replace the batteries. Figure 3 Backside Corrosion Detector 6 Technische Daten Corrosion Detector Portabel Power supply: Current input: Minimum conductivity: Measuring voltage: Measuring current: Measuring frequency: 4,5 VDC max. 60 ma 0,8 ms/cm 3,3 Vpp max. 1,7 ma 10 Hz Memory: Owner: 1 entry User: 50 entries Locations: 500 entries Measurements: 10,000 entries (circulating) Working temperature range: 10 C to +50 C Storage temperature: Housing: LxWxH: Weight: 25 C to +80 C (without batteries) Vestamid / black (antistatic) 180 x 85/62 x 30/25,5 mm 271 g Degree of protection: IP 66 Sealed keypad 21 keys (shielded) Compartment for 3 batteries size R6 (with special catch to EN 50014 requirement 9.2) Permitted batteries to IEC: LR6 or R6 Permitted rechargeable batteries: Type R6 or RS6 Ansmann, R6 or SR6 Saft, 601RS or 751RS Varta, P60AA or P750AA Panasonic Graphic display 128 x 64 and acryl glass cover (metalized) Connectors for the immersion probe and grounding clamp on face side of enclosure Electromagnetic compatibility (to IEC 801) CE mark 7 Note The Corrosion Detector Portable is equipped with an USB port, the hardware and software for documenting the measurements is in preparation. In its present condition, the unit has been prepared for approval for potentially hazardous atmospheres. Figure 4 Battery compartment open 10 Pfaudler Werke GmbH
Pfaudler Werke GmbH 11
The information provided in this documentation corresponds to the state of the art at the time of printing. It is published in good faith. However, we will accept no warranty claims based on the information provided in this documentation. We reserve the right to include improvements, amendments and new fi ndings in this documentation without prior notice. The actual design of products may deviate from the information contained in the calatoge if technical alterations and product improvements so require. The proposal made by Pfaudler for a concrete application will be binding in such cases. The present documentation is made available free of charge to our customers and other interested parties. The right to print or copy this documentation, or any parts thereof, or to convert the same into electronic form shall be subject to our written permission. All rights reserved by us. 338-1 e 02.08.xc by Robbins & Myers, Inc. Printed in Germany Pfaudler Werke GmbH Postfach 1780 D-68721 Schwetzingen Pfaudlerstraße D-68723 Schwetzingen Telefon +49 6202 85-0 Telefax +49 6202 22487 e-mail: service@pfaudler.de