BARTEC BENKE DPA-4.5 User manual

DA00EN MDH 10 A
December 2013
Distillation Process Analyzer DPA-4.5
Operating Manual

BARTEC BENKE GmbH
Borsigstraße 10
D-21456 Reinbek, Germany
Tel.: [phone]
Fax: [phone]
E-mail: [e-mail]
Internet: www.bartec-benke.de

Distillation Process Analyzer DPA-4.5
Contents
General information.......................................................................8
1.1 Information on the operating manual.............................8
1.2 Explanation of symbols..................................................9
1.3 Intended use................................................................11
1.4 Operator obligations ....................................................12
1.5 Limitation of liability......................................................13
1.6 Copyright......................................................................13
1.7 Replacement parts.......................................................14
1.8 Customer service.........................................................14
2Safety ....................................................................................15
2.1 Dangers and risks........................................................15
2.2 Hazardous substances ................................................18
2.3 Explosion protection ....................................................20
2.3.1 Marking ...........................................................20
2.3.2 Ignition protection types and certificates.........23
2.3.3 Special conditions...........................................24
2.4 Safety devices..............................................................25
2.4.1 Overview of safety devices on the analyzer ...26
2.4.2 Control box (Ex p)...........................................27
2.4.3 Measuring unit box (Ex d)...............................29
2.4.4 Junction boxes (Ex e) .....................................31
2.4.5 Potential equalization......................................31
2.4.6 Main switch and emergency off device...........32
2.4.7 Signs and safety warnings..............................32
2.5 Signs............................................................................33
2.5.1 Overview of signs............................................34
2.5.2 Warnings.........................................................36
2.5.3 Command signs..............................................37
2.6 Safety measures at the installation location................38
2.7 Safety information on explosion protection..................39
2.8 Personnel.....................................................................41
2.9 Personal protective equipment....................................43
2.10 Securing against being switched on again..................45
2.11 Behavior in dangerous situations and in the event of
an accident...................................................................46
3Technical data ......................................................................47
3.1 Measuring process ......................................................47
3.2 Explosion protection ....................................................48
3.3 Product flows ...............................................................48
3.4 Sample properties........................................................49
3.5 Auxiliary media.............................................................50
3.6 Electrical data ..............................................................51
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Distillation Process Analyzer DPA-4.5
Contents
3.7 Signal inputs and outputs.............................................52
3.8 Type plates...................................................................53
3.9 Operating and storage conditions................................55
3.10 Emissions.....................................................................56
3.11 Connections.................................................................56
3.12 General specifications..................................................57
4Design and function.............................................................58
4.1 Overview ......................................................................58
4.2 Brief description ...........................................................59
4.3 Measuring principle......................................................60
4.4 Description of subassemblies......................................62
4.4.1 Measuring unit.................................................62
4.4.2 Control unit......................................................64
4.4.3 Fluid technology..............................................66
4.4.4 Junction boxes ................................................68
4.4.5 Sample conditioning system (optional) ...........69
4.5 Optional extensions......................................................70
4.6 Connections.................................................................72
4.7 Operating elements......................................................73
5Transport, packaging and storage .....................................75
5.1 Safety instructions for transport...................................75
5.2 Symbols on the packaging...........................................77
5.3 Transport inspection.....................................................78
5.4 Packaging ....................................................................78
5.5 Center of gravity and suspension eyebolt....................79
5.6 Transport......................................................................80
5.7 Storage.........................................................................81
6Installation and preparation for commissioning...............82
6.1 Safety...........................................................................83
6.2 Requirements for the installation location....................85
6.3 Fixing to the floor..........................................................86
6.4 Mounting optional components....................................87
6.5 Connecting pipelines....................................................87
6.6 Connecting the power supply and signal lines.............92
6.7 Preparations for commissioning...................................95
6.7.1 Rinsing the instrument air and nitrogen
supply lines......................................................95
6.7.2 Supplying with instrument air and nitrogen.....96
6.7.3 Purging the cooling medium supply lines........97
6.7.4 Filling the chiller and supplying cooling
medium............................................................98
6.7.5 Rinsing the product supply lines ...................100
7Commissioning ..................................................................103
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Distillation Process Analyzer DPA-4.5
Contents
7.1 Safety.........................................................................103
7.2 Supplying with product...............................................105
7.3 Switching on the power supply..................................106
7.4 Monitoring and operation...........................................107
8Operation ............................................................................108
8.1 Safety.........................................................................108
8.2 Switching on...............................................................109
8.3 Operation ...................................................................110
8.4 Switching off...............................................................111
8.5 Shutting down in an emergency ................................112
9Faults...................................................................................113
9.1 Safety.........................................................................113
9.2 Diagnosis ...................................................................117
9.3 Fault table..................................................................118
9.4 Starting up after rectifying a fault...............................121
10 Maintenance .......................................................................122
10.1 Safety 122
10.2 Maintenance plan ......................................................126
10.3 Supplied tools and auxiliary equipment.....................127
10.4 Cleaning the touchscreen and other components.....128
10.5 Maintenance work......................................................129
10.5.1 General visual inspection..............................129
10.5.2 Checking the safety equipment ....................129
10.5.3 Checking the pressure monitor.....................131
10.5.4 Checking the residual-current device ...........131
10.5.5 Maintenance on the distillation flask.............132
Removing the distillation flask and
expansion tank...........................................133
Cleaning the distillation flask and bubble
pipe 136
Installing the distillation flask and
expansion tank...........................................137
10.5.6 Cleaning the flame arresters.........................141
10.5.7 Replacing the heating cartridges and/or flask
bottom temperature sensor...........................146
10.5.8 Replacing the battery of the industry PC ......149
10.6 Measures after maintenance.....................................151
11 Dismantling.........................................................................152
11.1 Safety 152
11.2 Preparations for dismantling......................................153
11.3 Disconnecting electrical connections.........................153
11.4 Disconnecting pipe connections................................154
11.5 Disposal.....................................................................156
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Distillation Process Analyzer DPA-4.5
Contents
12 Index....................................................................................157
6 December 2013

Distillation Process Analyzer DPA-4.5
General information
General information
1.1 Information on the operating manual
This operating manual provides important information on handling
the device. Adherence to all safety and operating instructions given
is the prerequisite for work safety.
−
Furthermore, the locally applicable accident prevention
regulations and general safety instructions for the area of
application of the device must be observed.
−
Read the operating manual prior to beginning any work! It is an
integral part of the product that must be stored in the
immediate vicinity of the device and must be accessible for
operating personnel at all times.
If the device is handed over to a third party, the operating manual
must also be handed over.
For the purposes of clarity, the figures in this operating manual are
not necessarily true to scale and may deviate slightly from the
actual device model.
NOTE
This operating manual is supplemented by the
PACS-Software DPA-4.5 handbook.
This document provides a detailed explanation of
the operation of the PACS software for controlling
the process analyzer. It also contains information
on the measuring process.
In addition to the operating manual and the software handbook, all
other documents contained in the customer folder are applicable.
Observe the safety instructions listed there. An overview can be
found in the table of contents in the customer folder.
8 December 2013

Distillation Process Analyzer DPA-4.5
General information
1.2 Explanation of symbols
Warnings Warnings are indicated in this operating manual by symbols. The
warnings are introduced with signal words indicating the degree of
danger at hand.
Observe the instructions under all circumstances and work with
care to avoid accidents, injuries to personnel and damage to
property.
DANGER
… indicates an imminent hazard which, if not
avoided, will result in serious injury or death.
WARNING
… indicates a potential hazard which, if not
avoided, can result in serious injury or death.
CAUTION
… indicates a potential hazard which, if not
avoided, can result in minor injury.
Tips and recommendations
NOTE
… indicates useful tips and recommendations as
well as information for efficient and trouble-free
operation.
CAUTION
… indicates a potential hazard which, if not
avoided, could result in damage to equipment or
property.
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Distillation Process Analyzer DPA-4.5
General information
Warning symbols The safety warnings on the device are also highlighted with
symbols. The following section explains the warning symbols used
on the device and in the operating manual.
Warning of a danger area
Warning about toxic substances
Warning about flammable substances
Warning about potentially explosive atmospheres
Warning about dangerous electrical current
Warning about potential hand injuries
Warning about hot surfaces
Examples of special warnings
DANGER!
Danger of death due to electrical current
... indicates life-threatening hazards due to electric
shock. Failure to observe the safety instructions
could result in serious injuries or death.
The work to be performed may only be carried out
by an electrician.
10 December 2013

Distillation Process Analyzer DPA-4.5
General information
WARNING
Risk of death due to loss of the explosion
protection
... indicates life-threatening situations in potentially
explosive atmospheres. Failure to observe the
safety instructions could result in serious injuries or
death.
Work may only be performed by a specialist for
potentially explosive atmospheres.
1.3 Intended use
The device is solely intended for use as a process analyzer for the
fully automatic measurement of the process of the distillation of
petroleum products.
The device is only to be used for stationary operation.
Every device is designed for up to three specific products and may
only be used to measure the distillation process of these products.
The following uses of the device are prohibited. They are regarded
as improper use:
−
Feeding other liquids, vapors or gases into the device; in
particular this applies to an external vent/drain system. Adding
oxygen or hydrogen can result in the risk of explosions.
−
Rinsing with steam. High temperatures and pressures damage
device components.
−
Feeding liquid gas and carbon dioxide into the device.
Do not make any modifications to the device. Only use
replacement parts from BARTEC BENKE. Otherwise additional
hazards may arise for which the safety equipment cannot provide
sufficient protection.
WARNING
Danger due to improper use
Every instance of improper use or usage for
purposes other than that for which the device is
expressly intended can result in dangerous
situations.
For this reason:
– Only use the device for its intended purpose.
– Adhere strictly to all specifications and
instructions in this operating manual at all times.
Claims of any type for damage that results from improper use are
excluded.
The operator bears sole liability for all damage resulting from
improper use.
December 2013 11

Distillation Process Analyzer DPA-4.5
General information
1.4 Operator obligations
The device is used in commercial enterprises. The operator of the
device therefore has a legal obligation to ensure work safety. The
applicable national laws and standards must be observed.
In addition to the work safety instructions in this operating manual,
the safety, accident prevention and environmental protection
regulations applicable in the area of application must be observed.
In addition to this, the operator is responsible for ensuring that the
device is always in a technically perfect working condition.
Therefore the following applies:
−
The operator must ensure that all maintenance intervals
specified in this operating manual are adhered to.
−
The operator must have all safety equipment inspected
regularly to ensure it is fully functional and complete.
−
The operator must make the necessary safety equipment
available to personnel.
12 December 2013

Distillation Process Analyzer DPA-4.5
General information
1.5 Limitation of liability
All specifications and instructions in this operating manual have
been compiled under due consideration of the applicable norms
and regulations and the latest technological standards as well as
our many years of experience and expertise.
The manufacturer assumes no liability for damage due to the
following:
−
Failure to observe the instructions in the operating manual
−
Improper use
−
Deployment of untrained personnel
−
Structural modifications made without prior consent
−
Technical modifications
−
Use of non-approved replacement parts
The actual scope of delivery of special models can differ from the
explanations and diagrams used in this manual if additional options
are ordered or due to the latest technical changes.
Otherwise, the obligations agreed upon in the delivery contract, the
general terms and conditions and the delivery terms of the
manufacturer apply, as well as any legal regulations valid at the
time the contract was concluded.
1.6 Copyright
The operating manual is to be treated confidentially. It is intended
exclusively for personnel engaged to work with the device. Making
the operating manual available to third parties is not permitted
without the manufacturer’s written consent.
NOTE
The information, texts, diagrams, images and other
illustrations of the contents are copyright protected
and subject to commercial protective rights. Every
instance of misuse may result in prosecution.
Reproductions of any type – including excerpts – as well as the
use for other purposes and/or communication of the content
without a written permission from the manufacturer are prohibited.
Infringements will be met with a claim for compensatory damages.
The right to make further claims is reserved.
December 2013 13

Distillation Process Analyzer DPA-4.5
General information
1.7 Replacement parts
WARNING
Risk of injury due to incorrect replacement
parts
Incorrect or defective replacement parts can result
in damage, faults or total failures as well as
impairments to safety.
For this reason:
– Only use original replacement parts from the
manufacturer.
Obtain replacement parts from authorized dealers or directly from
the manufacturer. The address can be found in section 1.8
“Customer service” on page 14.
The replacement parts list can be found in the customer folder.
1.8 Customer service
Should you require any technical information, our customer service
department will be happy to help you.
You can find information on the responsible contact partner at any
time by telephone, fax, e-mail or on the Internet.
Furthermore, our employees are always eager to receive any new
information and experiences arising from use and which could be
valuable for the improvement of our products.
Service address BARTEC BENKE GmbH
Borsigstraße 10
D-21456 Reinbek, Germany
Tel.: [phone]
Fax: [phone]
E-mail: [e-mail]
Internet: www.bartec-benke.de
14 December 2013

Distillation Process Analyzer DPA-4.5
Safety
2 Safety
This section provides an overview of all important safety aspects
for optimal protection of personnel as well as safe and trouble-free
operation.
Failure to observe the operating and safety instructions in this
manual can result in considerable dangers.
2.1 Dangers and risks
The following section names residual risks that have been
established in a risk analysis.
•
Adhere to the safety instructions and observe the warnings in
the following sections of this operating manual to reduce health
hazards and avoid dangerous situations.
Electrical current
DANGER
Danger of death due to electrical current
Touching voltage-conducting parts poses an
immediate life-threatening hazard. Damage to the
insulation or to individual components can cause
fatal injury.
For this reason:
– If the insulation is damaged, immediately
disconnect the power supply and have the
damage repaired.
– Have work on the electrical systems performed
only by electricians.
– For all work on the electrical systems, switch off
the voltage and test that the circuit is voltage-
free.
In addition to the device’s power supply, all
external voltages of signal and control lines
must also be free of voltage.
– Prior to any maintenance, cleaning or repair
work, turn off the power supply and secure the
device against being switched back on again.
– Do not bypass or disable any fuses. When
exchanging fuses, observe the correct
amperage.
– Keep moisture away from voltage-conducting
parts. This could otherwise result in a short-
circuit.
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Distillation Process Analyzer DPA-4.5
Safety
Liquids and gases under pressure
WARNING
Danger of injury due to liquids and gases under
pressure
Lines are under pressure. In case of defective or
leaking lines, escaping liquids could cause serious
injuries.
For this reason:
– Before performing any work, disconnect the
supply lines and depressurize them.
– Wear suitable protective goggles and gloves.
Hot operating materials
WARNING
Danger of burns due to hot operating materials
Operating materials can reach high temperatures
during operation and cause burns upon contact.
For this reason:
– Before handling operating materials, check
whether they are hot. Allow them to cool down if
necessary.
Hot surfaces
WARNING
Danger of burns due to hot surfaces
Contact with hot components can cause burns.
For this reason:
– Always wear protective clothing and gloves
during all work in the vicinity of hot components.
– Check that all components have cooled to
ambient temperature before beginning any work.
Suspended loads
WARNING
Danger of death due to suspended loads
Falling loads can result in severe injuries or death.
For this reason:
– Never step beneath suspended loads.
– Only move loads under supervision.
– Set down the load before exiting the workplace.
16 December 2013

Distillation Process Analyzer DPA-4.5
Safety
Dirt and objects left lying around
CAUTION
Danger of tripping due to dirt and objects left
lying around
Dirt deposits and objects left lying around
constitute slipping and stumbling hazards and can
cause injuries.
For this reason:
– Always maintain a clean and orderly work area.
– Remove objects that are no longer required.
– Draw attention to stumbling hazards with yellow
and black marking tape.
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Distillation Process Analyzer DPA-4.5
Safety
2.2 Hazardous substances
The information given here only provides a general overview of the
possible dangers that could arise from substances to be analyzed
in the system. For the precise material-specific requirements for
personal protective equipment, safety notices at the workplace,
cleaning and disposal, please refer to the data sheet pertaining to
the substance in use.
In addition to the hazardous substances used in the system, other
substances requiring further safety measures may also be in use at
the location of the device. It is the responsibility of the operator to
ensure compliance with the pertinent regulations and legislation
(for example the Ordinance on Hazardous Substances).
Highly flammable substances
Substance labeling
Flammable
WARNING
Danger of fire due to highly flammable
substances
Highly flammable liquids or gases can start fires
which can cause severe or fatal injuries.
For this reason:
– Do not use open flames or ignition sources.
– Keep a fire extinguisher at close hand.
– Stop work at once in the event of fire. Leave the
danger area until the all-clear signal is given.
18 December 2013

Distillation Process Analyzer DPA-4.5
Safety
WARNING
Danger of explosion
Petrochemical products can leak. The liquid
evaporates and forms an explosive atmosphere
when it mixes with air.
Highly flammable liquids can start fires which can
cause severe or fatal injuries.
For this reason:
– Do not use open flames or ignition sources.
– Take measures to prevent electrostatic charging.
– Do not use any tools which cause sparks.
– Additionally used devices and all electrical
connections within the danger area must be
protected against explosions in accordance with
ATEX (Directive 94/9/EC).
– Written permission (hot work permit) must be
obtained for all work with flames or hot materials.
– Keep a fire extinguisher at close hand.
– Stop work at once in the event of fire. Leave the
danger area until the all-clear signal is given.
Toxic substances
Substance labeling
Toxic
WARNING
Danger of injury from toxic substances
Swallowing, inhaling or contact with skin or eyes
can lead to serious, permanent health damage or
death.
For this reason:
– Avoid direct contact.
– Do not inhale vapors.
– If unknown concentrations or concentrations
above the limit values for the particular
substance are present in the air, wear suitable
respiratory protection.
– Wear appropriate protective clothing, gloves and
eye protection when working.
– In the event of an accident, consult a doctor at
once.
– Do not consume or store any food, drink or
tobacco in the work area.
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Distillation Process Analyzer DPA-4.5
Safety
Nitrogen
WARNING
Danger of suffocation due to nitrogen
Nitrogen can escape! A high concentration in the
air can result in the lack of oxygen. Inhalation can
cause the loss of consciousness or even death.
For this reason:
– Make sure the room is ventilated adequately.
– Wear suitable respiratory protection when
working on lines used for nitrogen, or shut off the
lines.
– If unknown concentrations or concentrations
above the limit values are present in the air, wear
suitable respiratory protection.
Environmentally hazardous
substances
Substance labeling
Hazardous to the aquatic environment
The substances in use are hazardous to the environment.
−
Prevent pollutants from entering water bodies, the sewage
system or the ground.
−
Drinking water can be contaminated by small quantities of
pollutants entering the ground and/or bodies of water.
−
Environmental pollution is also possible if larger quantities of
the substance are released into the atmosphere.
−
Residual quantities and waste must be disposed of
professionally.
−
If pollutant substances are released, take immediate measures
to limit the damage and inform the responsible authorities.
2.3 Explosion protection
2.3.1 Marking
The device is intended for use in potentially explosive
atmospheres. Depending on the required certification, it is marked
in accordance with
−
ATEX Directive 94/9/EC
−
National Electrical Code NEC 500/505 of the USA or the
Canadian Electrical Code CEC J18.
−
CSEx System from GOST-R
Marking according to ATEX 94/9/EC
II 2 G IIC T4 Gb (see type plate)
20 December 2013