Pfaudler 338-3 e User manual

338-3e

Corrosion Detector Portable

CDP EXProof ATEX

Operating Instructions

Content

1 Preface

2 General instructions

2.1 Intended use

2.2 Warnings contained in the

operating instructions

2.3 Notes on deliveries

2.4 Transport and storage

2.5 Notes on warranty

2.6 Notes on return deliveries

3 Safety

3.1 Proper use

3.2 Qualiﬁed personnel

3.3 Maintenance

4 Technical description

4.1 Components of the

measuring device

4.2 Mode of functioning of the

Corrosion Detector Portable

CDP EXProof

4.3 Properties of the measuring

device

4.4 Construction of the

immersion probe

4.5 Function of the grounding clamp

4.6 Limits of application

4.7 Menu structure: Corrosion

4.8 Operating concept

4.9 Start-up

4.10 Measurement

4.10.1 User

4.10.2 Test

4.10.3 Conductivity calculator

4.10.4 Setup

4.10.5 Archive:

4.11 Device status

4.12 Software

5 Replacing the batteries

6 Technical data

of Corrosion Detector

Portable CDP EXProof

2© Pfaudler GmbH

Corrosion Detector Portable CDP EXProof

1 Preface

The present operating instructions are

designed to familiarize users with the

equipment of the Corrosion Detector

Portable CDP EXProof 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 instruc-

tions without prior notice.

The actual design of products may

differ from the information provided

in the catalog if warranted by technical

modiﬁcations 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 transfor-

mation into electronic forms, in whole

or in part, shall require our written

approval.

2 General instructions

2.1 Intended use

The Corrosion Detector Portable (CDP)

may only be used for the inspection

of glass-lined vessels and internal parts

for damages and the resulting metal

corrosion. Apart from glass-lined reactors

and internal parts, it is also possible

to check reactors and internal parts with

other coatings (e.g., plastic material,

PTFE or rubber) for corrosion of metal.

The proper use of the device is described

in the present operating instructions.

All other applications of the device,

which are not described in the operating

instructions, are not permitted.

The measuring device is de-

signed for use in potentially explosive

atmospheres zone 1 and 2 according

to the directive 1999/92/EC. Non-

compliance with these instructions

may lead to dangerous conse-

quences. Please read the operating

instructions completely prior to using

the measuring device.

2.2 Warnings contained in the

operating instructions

In the operating instructions, the danger

symbol mis 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 speciﬁed on the shipping documents

attached to the shipment and corre-

sponds to the valid purchase agreement.

Check that the items delivered are

complete and intact.

2.4 Transport and storage

The Corrosion Detector Portable CDP

EXProof should be exclusively trans-

ported and stored in its closed original

case. In order to ensure an as-new con-

dition of the device and accessories,

the following storage conditions should

be maintained:

Storage/transport temperature:

–25 to +70°C without batteries

2.5 Notes on warranty

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, all parts must

be cleaned and decontaminated ﬁrst.

To protect our staff and for insurance

reasons, your return shipment must

be accompanied by a clearance certiﬁ-

cate on which you conﬁrm that the

immersion probes were properly

cleaned and decontaminated. You may

obtain a form sheet for this purpose

from us on request (OI332).

Since the device may be used

in potentially explosive atmos-

pheres, all explosion protection

requirements must be satisﬁed.

Repairs or modiﬁcations of the de-

vice are not permitted.

CDP EXProof

3 Safety

ATEX safety information

The present operating instructions con-

tain safety information and safety provi-

sions which must be complied with

in order to ensure the safe, reliable

operation of the CDP in potentially

explosive atmospheres under the condi-

tions described. Non-observance of the

information and instructions may lead

to serious consequences or violate appli-

cable laws. Please read the operating

instructions carefully prior to using the

measuring device. All instructions and

warnings in the manual must be observed

to ensure the safe operation of this

measuring device.

To avoid electric shocks or injuries while

working in potentially explosive atmos-

pheres, please follow and comply with

the following instructions:

■Do not open the CDP within poten-

tially explosive atmospheres.

■Replace the batteries of the CDP

outside potentially explosive atmos-

pheres only.

■Do not take spare batteries along into

potentially explosive atmospheres.

■Only use permitted batteries for the

C D P.

■Do not place the measuring device

in zone 0.

■The CDP may only be repaired by the

manufacturer.

■Use the CDP as described in the oper-

ating instructions exclusively, other-

wise the protective devices integrated

in the CDP may be impaired.

■Do not use the CDP when damaged.

Prior to using the CDP check the

housing for cracks or broken off plas-

tic parts.

■Prior to using the CDP always make

sure that the battery cover is closed

and ﬁxed.

■Do not use the CDP in case of mal-

functions. The safety precautions

may be impaired. Have the CDP

checked by the manufacturer in cases

of doubt.

■For operation of the CDP, only use the

permitted batteries and install them

properly in the housing. Please note the

instructions “Replacing the batteries”

in Section 5.

■Examine the measuring lines for dam-

aged insulation and exposed metal.

Test the continuity of the measuring

lines. Replace damaged measuring

lines prior to using the CDP.

■The storage case may not be taken

along into the potentially explosive

atmosphere.

Errors and inadmissible loads: If the safety

or integrity of the device is doubtful

or impaired, the device must be put

out of operation immediately and

removed from the potentially explosive

atmosphere. In addition, measures

must be taken to avoid the device from

being started up inadvertently before

it has been checked and declared to be ﬁt

for operation. It is recommended to send

the measuring device to the manufacturer

for inspection.

In the following cases, safety and relia-

bility of the measuring device may be

impaired and the device must not be

used anymore:

■Apparent damage to the housing of the

measuring device.

■The measuring device was exposed

to excessive loads for which it is not

designed.

■The device was stored inappropriately.

■The device has transport damages.

■Illegible display/labeling on the meas-

uring device.

■A measuring device malfunction

occurs.

3.1 Proper use

Any use of the equipment for purposes

other than those 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 instruc-

tions applicable to the electrical systems

and equipment and all explosion protection

provisions, if any.

3.2 Qualiﬁed 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 instruc-

tions – no matter whether intentionally

or negligently – releases Pfaudler Werke

GmbH from all liability and warranty

claims.

3.3 Maintenance

The Corrosion Detector Portable CDP

EXProof is maintenance-free. We recom-

mend an annual function test of the

device by the manufacturer. The function

test is documented at our company based

on the serial number and conﬁrmed

by a test certiﬁcate.

4© Pfaudler GmbH

4 Technical description

4.1 Components of the

measuring device

Check the items delivered for complete-

ness.

The following items are included in the

delivery:

■Hard-sided case with molded insert

taking up the measuring device

■Corrosion Detector Portable CDP

EXProof including batteries

■Immersion probe and reference

electrode

■Grounding clamp with contact moni-

toring

■Reference electrode (spare)

■File for cleaning contacts

■Operating instructions

■Software and hardware

4.2 Mode of functioning of the

Corrosion Detector Portable

CDP EXProof

If metal gets in contact with a conductive

liquid (electrolyte), the result is a voltaic

cell. That means that a voltage is gener-

ated at the contact surface between the

metal and the electrolyte. The value

of the voltage is subject to the type of the

metal, temperature 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 volt-

age. 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 speciﬁc

decomposition process which can be

electrically distinguished from that of

other metals.

The measuring device with the Corrosion

Detector Portable CDP EXProof as the

central element works with AC voltage,

thus avoiding electrochemical reactions

and the associated polarization at the

measuring electrodes.

The measuring loop consists of 4 elec-

trodes the 2 measuring electrodes,

the reference electrode and the reactor

wall as the 4th electrode.

OE = reference electrode

KW = reactor wall

4.3 Properties of the measuring

device

The device works according to the prin-

ciple of impedance analysis. That means:

the Corrosion Detector Portable CDP

EXProof will output an alarm only if

metal corrosion has actually occurred

on the reactor or the internal parts.

Compared to conventional glass moni-

toring equipment which works according

to the principle of conductivity analysis,

this method offers fundamental advan-

tages. 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 con-

ductive 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 deﬁned as a conductive

link between the product and the equi-

potential 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-speciﬁc operating condi-

tions, e.g., condensate bridges built up

via the reactor’s nozzles, or when ﬁlling

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 a corrosion alarm if they have been

properly installed and as long as the acids

used are corrosion-resistant.

4.4 Construction of the

immersion probe

The body of the immersion probe is

made of PTFE, the highly ﬂexible,

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 meas-

uring electrodes have been arranged

at a 180° offset. The exchangeable ref-

erence electrode (OE) has been screwed

into the lower part, which is closed

by a bulgy PTFE plug that prevents

contact between the reference elec-

trode 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 moni-

tor the cable and the positive contact

with the reactor or potential bonding

system.

4.6 Limits of application

Inappropriate products

Organic solvents, acetic acid, liquid

products or water with insufﬁcient

conductivity.

Aggressive media with insufﬁcient con-

ductivity, such as bromine or hydrogen

bromide.

Chemical resistance of the

immersion probe

The silicone cable and the measuring

electrodes are not suitable for perma-

nent use, however, they are resistant

to corrosion during short measure-

ments in acids at room temperature.

The exchangeable reference electrode

(OE) is not corrosion-resistant and will

be subject to varying degrees of attack,

depending on the acid. If erosion has

reached the O-ring seal, the reference

electrode must be renewed.

Corrosion Detector Portable CDP EXProof

4.7 Menu structure: Corrosion

Initial start-up

Select language

Date/Time

Owner

Corrosion Detector

Conductivity calc.

Test

Archive

Setup

29.06.07 08:00:00

Select User

Pfaudler\Schulz

Meier

Friedrich

Edit

Edit User

Company: Pfaudler

Name: Schulz

A/a ABC A/1

Select test location

Chemical\G22\R12345

Chemical\G22\R12361

Pfaudler\G98\R12379

Pfaudler\G99\R9988

Copy Edit

Edit location

Company: Chemical

Bldg: G22

Reactor: R12345

A/a ABC A/1

Fig. 3 Reactor with CPD

8© Pfaudler GmbH

Corrosion Detector Portable CDP EXProof

Once this data has been entered and con-

ﬁrmed, you will be requested to connect

the grounding clamp and the immersion

probe. If they have not been connected.

Start measurement.

When the measurement has been

started, the system checks whether

the conductivity and the acid value

of the reactor contents are sufﬁcient for

he measurement. If the corrosion poten-

tial is too low, the message Test not

possible – Add acid will be displayed

after a short while.

Add or remove the OE and KW measured

values by pressing the 0 key.

When the display appears red, the

message Test ﬁnished, CORROSION

will be displayed. Select No to repeat the

measurement and restart the process,

or save the values by hitting Yes.

LCD: red

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 ﬂashing.

LCD: red

Connect the grounding clamp to the

equipotential bonding system or a bare

conductor at the reactor. OK will be dis-

played if the clamp has been properly

connected.

For measurement it is necessary that

the immersion probe is fully immersed

in the medium. To locate the damage,

however, the immersion probe has

to be immersed to the deepest point.

Caution! Previously turn off the

agitator.

When the display appears green, the

message Test ﬁnished, No corrosion

will be displayed. Select No to repeat the

measurement and restart the process,

or save the values by hitting Yes.

LCD: green

mUp to 10,000 measurements

can be stored (circulating).

Now empty the reactor in batches; there

is no longer any contact if the display

ﬂashes green.

mCaution! Make sure that the

immersion probe does not get stuck

in the bottom valve.

LCD: ﬂashing red or green

Test nished

CORROSION

Locate spot?

No Yes

Test nished

No corrosion

Save test?

No Yes

Locate spot 44 s

CORROSION

Finished

Prepare measurement

Chemical\G22\R12345

Prepare measurement

Chemical\G22\R12345

Grounding clamp: OK

Immersion probe: OK

MEASURE

Test running

300s remaining

Cancel

Test nished

CORROSION

Save test?

No Yes

Corrosion Detector Portable CDP EXProof

4.10.3 Conductivity calculator

If water is used for testing the reactor,

the conductivity or acid value ﬁrst has

to be set to approx. 1mS in order

to obtain a reliable measurement.

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 m³. The necessary

quantity is indicated in kilos, and addi-

tionally in liters for the acid.

Select desired measurement and make

the desired entries using the Edit option

of the Note menu.

4.10.4 Setup

The following settings and controls can

be entered in the Setup menu.

System status: Software version, battery

voltage display, capacity and memory

allocation.

Language selection: Currently, German

and English are available.

LCD contrast: Individual contrast setting

adjustment.

Set time: Date and time input.

Owner: A new name can be entered

here if the owner changes.

Corrosion limit: The factory setting

is uncompensated. If materials are

used that are characterized by slight cor-

rosion under normal conditions already,

the sensitivity can be “compensated”

by selection.

4.10.5 Archive:

All measurements are stored in the

archive. When the measurement has

been completed, additional information

can be input under Note.

mOnly the measurements per-

formed by the active user will be

displayed in the archive.

mIf the alarm threshold

is changed, the proper functioning

of the unit should be veriﬁed by

simulating a damage.

4.11 Device status

In the main menu, the 0key can be used

to turn on and off all measuring data,

battery voltage and time.

4.12 Software

Refer to enclosed manufacturer’s in-

structions.

Conductivity calculator

Material: HCl

37 %

Reactor vol: 1.0 m3

Required 1.08 kg

quantity: 0.72 L

Entry 1/19

Chemical\G22\R12345

03.04.07 11:11:11

CORROSION

<Note>

Edit

Entry 1/19

Chemical\G22\R12345

03.04.07 11:11:11

CORROSION

Text

A/a ABC A/1

Status

Firmware: 1.0.10

Batterie: 4319 mV 81%

LCD contrast

>>> +2 <<<

>>> +1 <<<

>>> 0 <<<

>>> –1 <<<

>>> –2 <<<

Default

A/a ABC A/1

Corrosion Detector Portable CDP EXProof

5 Replacing the batteries

Do not open the measuring

device within potentially explosive atmos-

pheres. Replace the batteries outside

potentially explosive atmospheres only.

Use permitted batteries only.

Open the battery compartment on the

back of the unit and replace the batteries.

Use permitted batteries only.

6 Technical data of Corrosion Detector Portable CDP EXProof

EC type examination certiﬁcate: EX5 12 02 45670 008

Ex-identiﬁcation: II 2 G Ex ib IIB T3 –10 °C ≤ Ta ≤ +50°C

Power supply: 4.5 VDC

Current input: max. 60 mA

Minimum conductivity: 0,8mS/cm

Measuring voltage: 3,3 Veff

Measuring current: max. 1,3 mA

Measuring frequency: 10 Hz

Working temperature: –10°C bis +50 °C

Storage temperature: –25°C bis +70°C (without batteries)

Housing: Vestamide/black (antistatic)

LxWxH: 180 x 85/62 x 30/25.5 mm

Weight: 390 g

Degree of protection: IP 54

Memory: Owner: 1 entry

User: 50 entries

Locations: 500 entries

Measurements: 10,000 entries (circulating)

Sealed keypad: 21 keys (shielded)

Battery compartment for: 3 batteries size R6

Permitted batteries: AA 1.5 V size R6 LR6 No. 4106 AM3 MN 1500

VARTA Microbattery GmbH

Graphic display 128x64 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

Fig. 5 Battery compartment open

Fig. 4 Backside Corrosion Detector

Annex

EC Declaration of Conformity

Annex

EC Type Examination Certiﬁcate

Annex

EC Type Examination Certiﬁcate

EG-Baumusterprüfung

Notes

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 findings 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 there of, or to

convert the same into electronic form shall be subject to our

written permission.

Pfaudler GmbH

P.O. Box 1780 D-68721 Schwetzingen

Pfaudlerstraße D-68723 Schwetzingen

Phone +49 6202 85-233

Telefax +49 6202 85-273

E-mail [email protected]

www.pfaudler-instrumentation.com

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