BARTEC BENKE DPA-4.5 Operating Manual
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BARTEC BENKE DPA-4.5 Operating Manual

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

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  • Page 1 DA00EN MDH 10 A December 2013 Distillation Process Analyzer DPA-4.5 Operating Manual...
  • Page 2 BARTEC BENKE GmbH Borsigstraße 10 D-21456 Reinbek, Germany Tel.: +49 (0) 40 72703-0 Fax: +49 (0) 40 72703-363 E-mail: service@bartec-benke.de Internet: www.bartec-benke.de...

  • Page 3: Table Of Contents

    Distillation Process Analyzer DPA-4.5 Contents General information ............... 8 Information on the operating manual ......8 Explanation of symbols ..........9 Intended use ..............11 Operator obligations ............ 12 Limitation of liability ............13 Copyright ..............13 Replacement parts ............14 Customer service ............
  • Page 4 Distillation Process Analyzer DPA-4.5 Contents Signal inputs and outputs ..........52 Type plates ..............53 Operating and storage conditions ........55 3.10 Emissions ..............56 3.11 Connections ..............56 3.12 General specifications ..........57 Design and function .............58 Overview ..............58 Brief description ............59 Measuring principle ............60 Description of subassemblies ........62...
  • Page 5 Distillation Process Analyzer DPA-4.5 Contents Safety ................. 103 Supplying with product ..........105 Switching on the power supply ........106 Monitoring and operation ........... 107 Operation ................108 Safety ................. 108 Switching on............... 109 Operation ..............110 Switching off ............... 111 Shutting down in an emergency ........
  • Page 6 Distillation Process Analyzer DPA-4.5 Contents 12 Index ..................157 December 2013...

  • Page 8: General Information

    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.

  • Page 9: Explanation Of Symbols

    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.
  • Page 10 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...

  • Page 11: Intended Use

    − 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.

  • Page 12: Operator Obligations

    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.

  • Page 13: Limitation Of Liability

    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.

  • Page 14: Replacement Parts

    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: –...

  • Page 15: Safety

    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.
  • Page 16 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: –...
  • Page 17 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: –...

  • Page 18: Hazardous Substances

    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.
  • Page 19 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: –...

  • Page 20: Explosion Protection

    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: –...
  • Page 21 Distillation Process Analyzer DPA-4.5 Safety Meaning of marking according to ATEX 94/9/EC Marking Meaning The device may be used in potentially Device group II explosive atmospheres, except for those in mining. Category 2 A potentially explosive atmosphere may occasionally occur. The device ensures a high degree of safety and can be used in zone 1 and zone 2.
  • Page 22 Distillation Process Analyzer DPA-4.5 Safety Meaning of the labels according to NEC 500 / CEC J18 Marking Meaning Class I Classification of potentially explosive atmospheres in classes I (combustible gases, vapors and mist), II (dusts) and III (fibers and lint).

  • Page 23: Ignition Protection Types And Certificates

    Distillation Process Analyzer DPA-4.5 Safety 2.3.2 Ignition protection types and certificates The device and its components provide explosion protection by various types of ignition protection. The principles of these are briefly described in the following section: Pressurization Ex p The penetration of an external, potentially explosive atmosphere...

  • Page 24: Special Conditions

    Distillation Process Analyzer DPA-4.5 Safety The device is essentially made up of three main subassemblies, which are installed in the following boxes: Ignition protection type Control box Measuring unit box Power supply box Signal junction box The boxes and their installations have been ATEX-certified as individual subassemblies.

  • Page 25: Safety Devices

    Distillation Process Analyzer DPA-4.5 Safety 2.4 Safety devices WARNING Danger of death due to non-functioning safety devices Safety is only guaranteed if the safety devices are intact. For this reason: – Before starting work, check whether the safety devices are correctly installed and fully functional.

  • Page 26: Overview Of Safety Devices On The Analyzer

    Distillation Process Analyzer DPA-4.5 Safety 2.4.1 Overview of safety devices on the analyzer Figure 2.1: Locations of the safety equipment Locking screw for measuring unit box cover Key switch Lock on power supply box Ground Catch Catch with safety bolt...

  • Page 27: Control Box (Ex P)

    Distillation Process Analyzer DPA-4.5 Safety 2.4.2 Control box (Ex p) The control box (Ex p) contains operating equipment without its own ignition protection type and therefore contains potential ignition sources. The control box is pressurized for explosion protection (Ex p).
  • Page 28 Distillation Process Analyzer DPA-4.5 Safety WARNING Explosion protection is not provided when the pressure monitor is switched off The control box contains ignition sources. Operating the device when the pressure monitor of the control box is switched off can result in explosions in potentially explosive atmospheres.

  • Page 29: Measuring Unit Box (Ex D)

    Distillation Process Analyzer DPA-4.5 Safety 2.4.3 Measuring unit box (Ex d) The measuring unit box (Ex d) contains operating equipment without its own ignition protection type and therefore contains potential ignition sources. In addition, the box contains failsafe and non-failsafe pipeline systems for the product and auxiliary media.
  • Page 30 Distillation Process Analyzer DPA-4.5 Safety Opening the box The measuring unit box can be opened for service and maintenance work: WARNING Danger of explosion due to ignition sources inside Hot surfaces in the interior can ignite an explosive atmosphere. For this reason: –...

  • Page 31: Junction Boxes (Ex E)

    Distillation Process Analyzer DPA-4.5 Safety 2.4.4 Junction boxes (Ex e) The signal junction box contains terminals for connecting the signal lines. Note: The exposed terminal connections are still live even when the device is switched off. Explosion protection is provided for the signal junction box by the increased safety ignition protection (Ex e) in closed condition only.

  • Page 32: Main Switch And Emergency Off Device

    Distillation Process Analyzer DPA-4.5 Safety 2.4.6 Main switch and emergency off device Main switch and integration in an The device has neither its own main switch nor its own emergency emergency off concept required off device. For this reason, before commissioning the device: •...

  • Page 33: Signs

    Distillation Process Analyzer DPA-4.5 Safety 2.5 Signs The following safety instructions and signs giving orders must be attached directly to the device. They must be attached in the position in which they are delivered and must be clearly legible. WARNING...

  • Page 34: Overview Of Signs

    Distillation Process Analyzer DPA-4.5 Safety 2.5.1 Overview of signs Figure 2.6: Warnings on the outside Warning: “Danger of explosion due to ignition sources inside – wait 25 minutes” Warning: “Danger of explosions due to electrostatic discharge” Warning: “Do not touch parts that are not intrinsically safe”...
  • Page 35 Distillation Process Analyzer DPA-4.5 Safety Figure 2.7: Warnings inside the measuring unit box Warning: “Danger of injury from fluids under pressure” Warning about hot surfaces Warning about dangerous electrical current Sign for wearing safety gloves Sign for wearing safety goggles...

  • Page 36: Warnings

    Distillation Process Analyzer DPA-4.5 Safety 2.5.2 Warnings Danger of explosion Sticker 1 (see p. 34) WARNING Danger of explosion due to ignition sources inside Hot surfaces inside the measuring unit box can ignite an explosive atmosphere. For this reason: – Turn off the power supply before opening and wait for 25 minutes.

  • Page 37: Command Signs

    Distillation Process Analyzer DPA-4.5 Safety Danger of death due to electrical current Sticker 3 (see p. 34) DANGER Danger of death due to electrical current If live parts that are not intrinsically safe are touched, life-threatening current can flow. For this reason: –...

  • Page 38: Safety Measures At The Installation Location

    Distillation Process Analyzer DPA-4.5 Safety Eye protection Sticker 9 (see p. 35) This sign indicates that suitable safety goggles must be worn (see also p. 43). Hearing protection This sign indicates that suitable ear protectors must be worn (see also p. 43) and is located on the control box (when the control box cooling option is installed).

  • Page 39: Safety Information On Explosion Protection

    Distillation Process Analyzer DPA-4.5 Safety 2.7 Safety information on explosion protection Petrochemical products WARNING Danger of explosions due to impermissible petrochemical products The explosion protection of the individual devices has been exclusively designed for the safety technology characteristics of the petrochemical products specified in the order documentation.
  • Page 40 Distillation Process Analyzer DPA-4.5 Safety Opening the control box WARNING Danger of explosion due to open sources of ignition The control box contains ignition sources. Opening in potentially explosive atmospheres can cause explosions. – Before opening, ensure that no potentially explosive atmosphere is present.

  • Page 41: Personnel

    Distillation Process Analyzer DPA-4.5 Safety 2.8 Personnel All personnel who may work in potentially explosive atmospheres must be sufficiently trained and familiar with the device. This training must include instruction on the device properties, hazardous substances and environmental conditions that relate to the requirements for explosion protection.
  • Page 42 Distillation Process Analyzer DPA-4.5 Safety WARNING Hazard for unauthorized persons Unauthorized persons who do not fulfill the requirements described here are not aware of the hazards posed in the work area. For this reason: – Keep unauthorized persons out of the work area.

  • Page 43: Personal Protective Equipment

    Distillation Process Analyzer DPA-4.5 Safety 2.9 Personal protective equipment Wearing personal protective equipment while working is required in order to minimize health hazards. • During work, always wear the safety equipment required for the respective task. • Follow the instructions posted in the work area regarding personal protective equipment.
  • Page 44 Distillation Process Analyzer DPA-4.5 Safety For special work, wear When you are performing special tasks, special personal protective equipment is required. This equipment is referred to specifically in the individual chapters of this operating manual. These special items of safety equipment are described below:...

  • Page 45: Securing Against Being Switched On Again

    Distillation Process Analyzer DPA-4.5 Safety 2.10 Securing against being switched on again DANGER Danger of death due to unauthorized restarting During work in danger areas, there is the danger that the power supply can be switched on without authorization. This poses a life-threatening hazard for the persons in the danger area.

  • Page 46: Behavior In Dangerous Situations And In The Event Of An Accident

    Distillation Process Analyzer DPA-4.5 Safety 2.11 Behavior in dangerous situations and in the event of an accident − Always be prepared for accidents or fire. Preventive measures − Keep first aid equipment (first aid kit, blankets, etc) and fire extinguishers (ABC powder) within immediate reach.

  • Page 47: Technical Data

    Distillation Process Analyzer DPA-4.5 Technical data 3 Technical data 3.1 Measuring process Specification Device type DPA-4.5 Variant „Low Pressure“ DPA-4.5 LowP Measuring at reduced pressure Measured variable Distillation performance (distillate quantity according to the temperature) Measuring process Batch distillation at atmospheric pressure Measuring range 20 ...

  • Page 48: Explosion Protection

    Distillation Process Analyzer DPA-4.5 Technical data 3.2 Explosion protection Marking according to ATEX 94/9/EC II 2 G IIC T4 Gb (see type plate) 3.3 Product flows Possible product flows Up to three product flows for measurement in the process Up to three validation flows for checking the measurements...

  • Page 49: Sample Properties

    Distillation Process Analyzer DPA-4.5 Technical data 3.4 Sample properties Specification Inlet pressure Minimum 1 bar Maximum 2 bar Back-pressure Below primary pressure, 1 bar maximum Inlet temperature, maximum Groups 1 to 3 (ASTM D 86) 18 °C Group 4 (ASTM D 86) 23 °C or 9 …...

  • Page 50: Auxiliary Media

    Distillation Process Analyzer DPA-4.5 Technical data 3.5 Auxiliary media Purging gas for control box Instrument air Primary pressure, 2 … 7 bar minimum – maximum for DPA-4.5 LowP: minimum 6 bar Consumption, normal operation, 1.0 Nm typical for DPA-4.5 LowP: minimum 9.5 Nm³/h...

  • Page 51: Electrical Data

    Distillation Process Analyzer DPA-4.5 Technical data Cooling medium Water or water-glycol mixture Not required for cooling with Primary pressure 2.5 … 3.5 bar optional chiller Difference between primary 2.5 … 3.5 bar, then max. pressure and return pressure primary pressure 7 bar...

  • Page 52: Signal Inputs And Outputs

    Distillation Process Analyzer DPA-4.5 Technical data 3.7 Signal inputs and outputs Analog inputs Signal 4 … 20 mA 160 Ω Apparent ohmic resistance, maximum Reference potential 0 V / ground Digital inputs Voltage High 15 … 28 V DC 0 … 4 V DC...

  • Page 53: Type Plates

    Distillation Process Analyzer DPA-4.5 Technical data 3.8 Type plates Primary type plate The primary type plate is located on the cover of the power supply box and contains the following information: − Manufacturer − Type − Explosion protection marking − Serial number −...
  • Page 54 Distillation Process Analyzer DPA-4.5 Technical data Control box The type plate for the control box is on the left side of the control box door and includes the following specifications: − Manufacturer − Type − Explosion protection marking − Certificate number −...

  • Page 55: Operating And Storage Conditions

    Distillation Process Analyzer DPA-4.5 Technical data 3.9 Operating and storage conditions Ambient temperature Operation 5 … 40 °C Storage -20 … 60 °C Humidity Operation 5 … 80% Storage 5 … 85% December 2013...

  • Page 56: Emissions

    Distillation Process Analyzer DPA-4.5 Technical data 3.10 Emissions Noise emissions Basic device < 70 dB(A) Device with optional control box cooling 85 dB(A) Substance emissions Liquid Petrochemical product, discharged via drain Gaseous Petrochemical product, purging gas and bubble gas discharged via vent...

  • Page 57: General Specifications

    Distillation Process Analyzer DPA-4.5 Technical data 3.12 General specifications Weight Device (without optional features) 250 kg Chiller (optional) 100 kg Dimensions Width 1,140 mm Height 1,900 mm Depth 710 mm December 2013...

  • Page 58: Design And Function

    Distillation Process Analyzer DPA-4.5 Design and function 4 Design and function 4.1 Overview Figure 4.1: Analyzer with chiller Measuring unit box Signal junction box Touchscreen Chiller (optional) Control box Frame Power supply box Fluid system December 2013...

  • Page 59: Brief Description

    Distillation Process Analyzer DPA-4.5 Design and function 4.2 Brief description The device is used to determine the distillation sequence of mineral oil products at atmospheric pressure. The device is a process analyzer. It measures the distillation process fully automatically in cycles, in a similar manner as with: −...

  • Page 60: Measuring Principle

    Variant LowP At the DPA-4.5 LowP the compartment is supplied with vacuum before starting the distillation. The complete distillation takes place under reduced pressure. Thus, the final boiling point of the product is lowered (according to ASTM D 86 the FBP may not exceed 400 °C).
  • Page 61 Distillation Process Analyzer DPA-4.5 Design and function ASTM D 86 and distillation groups The mineral oil products are split up into four distillation groups in ASTM D 86. The assignment to a group depends on the composition and expected volatility properties of the product. The assignment to a group determines the product’s inlet temperature and the cooling...

  • Page 62: Description Of Subassemblies

    Distillation Process Analyzer DPA-4.5 Design and function 4.4 Description of subassemblies 4.4.1 Measuring unit Overview Outlet filter Cooling pipe Flame arrester for instrument air Flame arrester for bubble gas Receiver Inlet flame arrester for product Metering pump Vent flame arrester...
  • Page 63 Distillation Process Analyzer DPA-4.5 Design and function Outlet filter The outlet filter (1) protects the outlet flame arrester (9) from any residue from the distillation flask. Measuring unit box (Ex d) and Together with the flame arresters, the measuring unit box (10)

  • Page 64: Control Unit

    Distillation Process Analyzer DPA-4.5 Design and function 4.4.2 Control unit Figure 4.3: Outside of the control box Stylus for touchscreen Touchscreen Pressure monitor display Explosion protection switch The pressurized enclosure of the control box also contains all electrical and electronic components necessary for controlling the device.
  • Page 65 Distillation Process Analyzer DPA-4.5 Design and function Figure 4.4: Inside of the control box Industry PC Motor circuit breaker for chiller (optional) Automatic cut-outs The electrical and electronic components are: − Industry PC that provides the user interface, controls and monitors all processes and performs external communications.

  • Page 66: Fluid Technology

    Distillation Process Analyzer DPA-4.5 Design and function 4.4.3 Fluid technology The fluid technology subassembly contains components for regulating the pressure and filtering the required instrument air and bubble gas (nitrogen). To protect the cooling pipe circuit, a filter unit is installed for filtering the cooling medium. If the optional receiver tempering is installed, there will normally be a needle valve for adjusting the flow of cooling medium through the receiver.
  • Page 67 Distillation Process Analyzer DPA-4.5 Design and function Fluid technology DPA-4.5 LowP Figure 4.6 Fluid technology for DPA-4.5 LowP Vacuum ejector Pressure regulator pressure regulator purging gas Bubble gas pressure Cooling medium filter regulator Pressure monitor pressure regulator December 2013...

  • Page 68: Junction Boxes

    Distillation Process Analyzer DPA-4.5 Design and function 4.4.4 Junction boxes The device is connected to the supply and signal voltages via two separate junction boxes: The power supply box contains the terminals for connecting the power supply, contactors and a control unit.

  • Page 69: Sample Conditioning System (Optional)

    Distillation Process Analyzer DPA-4.5 Design and function 4.4.5 Sample conditioning system (optional) Overview Figure 4.8: Sample conditioning system (example) Sample flow meter 10 Sampling ball valve Cooling medium flow 11 Drain meter Coalescer flow meter Coalescer Two redundant fine filters...

  • Page 70: Optional Extensions

    Distillation Process Analyzer DPA-4.5 Design and function 4.5 Optional extensions The validation system consists of a tank, a pump, one or several Validation system valves and further components. The valves are operated manually or controlled by the PACS control software.
  • Page 71 Distillation Process Analyzer DPA-4.5 Design and function Control box cooling At a higher ambient temperature, impermissibly high temperatures can occur on the inside of the control box. To prevent this, the box can be equipped with a vortex cooler. Serial interface Serial interface for data exchange.

  • Page 72: Connections

    Design and function 4.6 Connections Figure 4.9: Connections Product outlet (drain) Cooling medium outlet Vent Instrument air inlet DPA-4.5 LowP: second separate vent Validation product inlet Cooling medium inlet Product inlet Signal junction box Nitrogen inlet Power supply box December 2013...

  • Page 73: Operating Elements

    Distillation Process Analyzer DPA-4.5 Design and function 4.7 Operating elements To prevent potentially explosive atmospheres from developing, overpressure is created with the aid of instrument air in the interior of the control box. The overpressure is monitored by a pressure monitor. For servicing and maintenance work, monitoring can be switched off using the key switch on the front side of the control box.
  • Page 74 The pressure regulator protects against particles and moisture entering the instrument air or nitrogen in the event of a fault. Pressure regulators are used for Vacuum ejector for DPA-4.5 LowP Bubble gas (nitrogen) Pressure monitor Purging gas Figure 4.12: Pressure regulator with...

  • Page 75: Transport, Packaging And Storage

    Distillation Process Analyzer DPA-4.5 Transport, packaging and storage 5 Transport, packaging and storage 5.1 Safety instructions for transport Improper transport CAUTION Damage due to improper transport Improper transport can result in considerable material damage. For this reason: – When unloading the packaged items during...
  • Page 76 Distillation Process Analyzer DPA-4.5 Transport, packaging and storage WARNING Danger of injury from transport item swinging The suspension point is not directly over the center of gravity of the device. The item swings out when transported with a crane and can cause injury to personnel or material damage if adequate space to maneuver is not provided.

  • Page 77: Symbols On The Packaging

    Distillation Process Analyzer DPA-4.5 Transport, packaging and storage 5.2 Symbols on the packaging This way up The arrows indicate the top side of the packaged item. They must always point upwards; otherwise the content can be damaged. Protect against moisture Protect the packaged items against moisture and store in a dry place.

  • Page 78: Transport Inspection

    Distillation Process Analyzer DPA-4.5 Transport, packaging and storage 5.3 Transport inspection Inspect the delivery immediately upon receipt for completeness and possible transport damage. If externally visible transport damage is detected, proceed as follows: − Do not accept the delivery or only accept it with reservations.

  • Page 79: Center Of Gravity And Suspension Eyebolt

    Distillation Process Analyzer DPA-4.5 Transport, packaging and storage 5.5 Center of gravity and suspension eyebolt Figure 5.1: Center of gravity Suspension eyebolt Center of gravity − with chiller (HxLxD): approx. 900 x 590 x 330 mm December 2013...

  • Page 80: Transport

    Distillation Process Analyzer DPA-4.5 Transport, packaging and storage 5.6 Transport Transport with a forklift The device can be transported with a forklift under the following conditions: (device in the packaging) − The device must be in its packaging (wooden box or crate with integrated pallet).

  • Page 81: Storage

    Distillation Process Analyzer DPA-4.5 Transport, packaging and storage 5.7 Storage Only store the device where the following conditions are fulfilled: − Only store in the original packaging. − Do not store outdoors. − Store in a dry and dust-free location.

  • Page 82: Installation And Preparation For Commissioning

    Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning 6 Installation and preparation for commissioning WARNING Danger due to incorrect installation and commissioning! Installation and commissioning must be conducted by trained specialist personnel who have adequate experience. Errors in installation can lead to life- threatening situations or considerable material damage.

  • Page 83: Safety

    Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning 6.1 Safety − Installation and preparations for commissioning are only to be Personnel performed by specialists for potentially explosive atmospheres. − Have work on the electrical system performed only by electricians.
  • Page 84 Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning 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: –...

  • Page 85: Requirements For The Installation Location

    Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning 6.2 Requirements for the installation location Ambient conditions The device is solely intended for use at a fixed location in an analysis building that provides protection against the elements. The following ambient conditions must be met:...

  • Page 86: Fixing To The Floor

    Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning Notes on optional components NOTE If the chiller is installed, keep a space of 0.5 m free on the right and left so that the ventilation of the chiller is not impaired.

  • Page 87: Mounting Optional Components

    Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning 6.4 Mounting optional components Specify optional components when ordering the device. Possible options are listed in the Design and function chapter. Retrofitting components may only be performed by the manufacturer or by persons authorized by the manufacturer.
  • Page 88 Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning Liquids and gases under pressure WARNING Danger of injury due to liquids and gases under pressure Lines in the interior are still under pressure even if the device is switched off. In case of defective or leaking lines, escaping liquids could cause serious injuries.
  • Page 89 Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning 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.
  • Page 90 Product that condensates in the vent line can thus also flow off to the drain line during normal operation. NOTE For DPA-4.5 LowP a separate vent line is necessary. B. Separated vent and drain Alternatively, the vent can be completely separated from the drain: •...
  • Page 91 Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning Sample conditioning system (optional) NOTE If the sample conditioning system is installed, observe the following additional instructions for connecting pipe fittings. • The product inlet is a part of the sample conditioning system.

  • Page 92: Connecting The Power Supply And Signal Lines

    Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning 6.6 Connecting the power supply and signal lines − This work should only be performed by a qualified electrician. − Special tools required: − Electrician’s equipment The following tightening torques apply:...
  • Page 93 Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning Main switch and integration in an The device has neither its own main switch nor its own emergency emergency off concept required off device. For this reason, before commissioning the device: •...
  • Page 94 Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning Connecting the power supply 1. Connect the device to the local potential equalization with a cable cross-section of at least 16 mm For the position of the connections on the rack, please refer to the installation plan in the customer folder.

  • Page 95: Preparations For Commissioning

    Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning 6.7 Preparations for commissioning Before commissioning, rinse the supply lines: − Instrument air − Nitrogen − Cooling medium (not necessary for devices with optional chiller) − Product Rinsing is intended to remove dirt and air from the supply lines and is only necessary during commissioning or after maintenance or repair work to the supply lines.

  • Page 96: Supplying With Instrument Air And Nitrogen

    The analyzer is now supplied with instrument air. • Additionally set the vacuum ejector pressure regulator (1) to the target value for DPA-4.5 LowP (see page 50). Figure 6.1: Pressure regulator for instrument air (3, 4) and nitrogen (2) Supplying with nitrogen Nitrogen is required for adding it to the distillation flask during the distillation process and for measuring the fill level.

  • Page 97: Purging The Cooling Medium Supply Lines

    Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning 6.7.3 Purging the cooling medium supply lines The cooling pipe and, depending on the product, the receiver receiver tempering option) need to be cooled. This requires a cooling medium. Cooling can take place −...

  • Page 98: Filling The Chiller And Supplying Cooling Medium

    Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning 6.7.4 Filling the chiller and supplying cooling medium Devices with the optional chiller do not require any external cooling medium (see page 97). NOTE Fill the chiller with cooling medium on commissioning.
  • Page 99 Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning Supplying with cooling medium Make sure that: − The properties of the cooling medium, in particular pressure and temperature, correspond to the specifications in the installation plan and technical data. − The cooling medium supply lines are clean (see page 97).

  • Page 100: Rinsing The Product Supply Lines

    Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning 6.7.5 Rinsing the product supply lines All product supply lines must be rinsed. This also applies to the validation product. NOTE Observe the regulations for mounting screw pipe connections. See manufacturer's documentation of the corresponding component.
  • Page 101 Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning 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.
  • Page 102 Distillation Process Analyzer DPA-4.5 Installation and preparation for commissioning 9. Dispose of the product in the collection container professionally. • Rinse all product and validation product supply lines as described above. • Check the connections for leaks (visual inspection). December 2013...

  • Page 103: Commissioning

    Distillation Process Analyzer DPA-4.5 Commissioning 7 Commissioning NOTE BARTEC BENKE recommends that commissioning be performed by employees of the manufacturer and that operating and maintenance personnel be trained by the manufacturer. • Make sure that all preparatory work for commissioning has been performed.
  • Page 104 Distillation Process Analyzer DPA-4.5 Commissioning Liquids and gases under pressure WARNING Danger of injury due to liquids and gases under pressure Lines in the interior are still under pressure even if the device is switched off. In case of defective or leaking lines, escaping liquids could cause serious injuries.

  • Page 105: Supplying With Product

    Distillation Process Analyzer DPA-4.5 Commissioning 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.

  • Page 106: Switching On The Power Supply

    Distillation Process Analyzer DPA-4.5 Commissioning 7.3 Switching on the power supply • Preparation Check all safety equipment. You can find information in this regard in the Maintenance chapter on page 129. • Check connections for leaks. • Make sure that the pressure and flow of the instrument air are set correctly.

  • Page 107: Monitoring And Operation

    Distillation Process Analyzer DPA-4.5 Commissioning 7.4 Monitoring and operation • Monitoring After 2 hours of operation, check all connections for leaks and make a general visual inspection (see page 129). Supplying with product: • Check the setting on the system-side pressure regulator. If necessary, re-adjust the pressure regulator.

  • Page 108: Operation

    Distillation Process Analyzer DPA-4.5 Operation 8 Operation 8.1 Safety Fundamental principles WARNING Danger of injury due to improper operation Improper operation can lead to serious personal injury and material damage. For this reason: – All operating steps are to be conducted in accordance with the instructions contained in this operating manual.

  • Page 109: Switching On

    Distillation Process Analyzer DPA-4.5 Operation NOTE Further safety-relevant notes on explosion protection, hazardous substances and handling the device can be found in the Safety chapter. 8.2 Switching on Preparation Make sure that: − All safety equipment is installed and fully functional (see page 129).

  • Page 110: Operation

    Distillation Process Analyzer DPA-4.5 Operation 8.3 Operation − In normal operating circumstances, the analyzer works fully Operation automatically. − The analysis process can be followed on the analyzer’s touchscreen. − The analyzer can be operated with the touchscreen stylus. NOTE...

  • Page 111: Switching Off

    Distillation Process Analyzer DPA-4.5 Operation 8.4 Switching off NOTE For detailed information on operating the analyzer with the touchscreen and stylus, please refer to the software handbook. • Procedure Using the stylus, click the menu command File in the PACS software on the touchscreen.

  • Page 112: Shutting Down In An Emergency

    Distillation Process Analyzer DPA-4.5 Operation 8.5 Shutting down in an emergency NOTE Follow the local safety regulations. • Shutting down Activate the emergency off device. The analyzer is disconnected from the power supply. • Close the valves in the product supply line.

  • Page 113: Faults

    Distillation Process Analyzer DPA-4.5 Faults 9 Faults The following chapter describes the possible causes of faults and the work required to rectify them. If faults occur frequently, the maintenance intervals must be shortened according to the actual load. If the faults cannot be remedied with the following instructions,...
  • Page 114 Distillation Process Analyzer DPA-4.5 Faults Fundamental principles WARNING Danger of injury due to improper fault rectification Improper fault rectification can lead to serious personal injury and material damage. For this reason: – Before starting work, ensure there is adequate space for the work.
  • Page 115 Distillation Process Analyzer DPA-4.5 Faults Securing against being switched on again DANGER Danger of death due to unauthorized restarting During work to rectify faults, there is the danger that the power supply can be switched on without authorization. This poses a life-threatening hazard for the persons in the danger area.
  • Page 116 Distillation Process Analyzer DPA-4.5 Faults Liquids and gases under pressure WARNING Danger of injury due to liquids and gases under pressure Lines in the interior are still under pressure even if the device is switched off. In case of defective or leaking lines, escaping liquids could cause serious injuries.

  • Page 117: Diagnosis

    Distillation Process Analyzer DPA-4.5 Faults 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.

  • Page 118: Fault Table

    Distillation Process Analyzer DPA-4.5 Faults 9.3 Fault table Faults not listed here may only be diagnosed and rectified by the manufacturer or specialists authorized by the manufacturer. 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.
  • Page 119 Distillation Process Analyzer DPA-4.5 Faults Fault Possible cause Troubleshooting No ready signal / Unsuitable parameter settings Adjust the parameters measuring result for a (see software handbook). long time Signal cable connection to device has been Rectify the cause of the fault.
  • Page 120 Distillation Process Analyzer DPA-4.5 Faults Fault Possible cause Troubleshooting flowing out of the The drain in the base of the distillation flask is Clean the distillation flask distillation flask or blocked. (see page 132). only very slowly The outlet flame arrester for the product is Clean flame arrester blocked.

  • Page 121: Starting Up After Rectifying A Fault

    Distillation Process Analyzer DPA-4.5 Faults 9.4 Starting up after rectifying a fault After rectifying a fault, conduct the following steps for restarting: • Reset the emergency off device. • If necessary, acknowledge the alarms issued by the process software PACS (see software handbook).

  • Page 122: Maintenance

    − Work on the electrical systems may only be performed by electricians. NOTE BARTEC BENKE recommends that operating and maintenance personnel be trained by the manufacturer. Personal protective equipment The following protective equipment is to be worn for all maintenance work: −...
  • Page 123 Distillation Process Analyzer DPA-4.5 Maintenance 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: – For all work on the electrical systems, switch off the voltage and test that the circuit is voltage- free.
  • Page 124 Distillation Process Analyzer DPA-4.5 Maintenance Liquids and gases under pressure WARNING Danger of injury due to liquids and gases under pressure Lines in the interior are still under pressure even if the device is switched off. In case of defective or leaking lines, escaping liquids could cause serious injuries.
  • Page 125 Distillation Process Analyzer DPA-4.5 Maintenance 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.

  • Page 126: Maintenance Plan

    Distillation Process Analyzer DPA-4.5 Maintenance 10.2 Maintenance plan The following sections describe the maintenance work required for optimum and trouble-free operation. If increased wear is detected at regular inspections, the required maintenance intervals should be shortened according to the actual degree of observed wear.

  • Page 127: Supplied Tools And Auxiliary Equipment

    Distillation Process Analyzer DPA-4.5 Maintenance Interval Maintenance work To be performed by Replace fan Every 5 years Replace lithium battery for PC 10.3 Supplied tools and auxiliary equipment A toolbox is supplied for maintenance, containing the following items: Figure 10.1: Toolbox Spare pneumatic hose 6/4 mm 3.9 mm cotter pin driver for heating cartridges...

  • Page 128: Cleaning The Touchscreen And Other Components

    Distillation Process Analyzer DPA-4.5 Maintenance 10.4 Cleaning the touchscreen and other components Safety WARNING Danger of explosions due to static discharge Cleaning the plastic surfaces, in particular the touchscreen, using a dry cloth can result in static discharge. Any sparks could ignite a potentially explosive atmosphere.

  • Page 129: Maintenance Work

    Distillation Process Analyzer DPA-4.5 Maintenance 10.5 Maintenance work The following maintenance work must be carried out according to the maintenance plan. 10.5.1 General visual inspection − The inspection can be performed while the analyzer is in Procedure operation. − Inspect the device for externally visible problems in accordance with the following table.
  • Page 130 Distillation Process Analyzer DPA-4.5 Maintenance Inspection table Safety equipment Target state Warning signs Present, easy to read Stickers Present, easy to read Key switch for Ex protection Position On No damage to the housing or Control box installations No open drill holes...

  • Page 131: Checking The Pressure Monitor

    Distillation Process Analyzer DPA-4.5 Maintenance 10.5.3 Checking the pressure monitor − This may only be performed by a qualified electrician. − Safety goggles Personal protective equipment − Safety gloves (hazardous substances) − Software handbook Required material − Electrical engineering documents (see customer folder) •...

  • Page 132: Maintenance On The Distillation Flask

    Use a slightly angled pipe as a nozzle. NOTE The distillation flask can also be cleaned by the manufacturer. To do this, send the distillation flask to BARTEC BENKE. You can find contact details on page 14. − Safety goggles Personal protective equipment −...

  • Page 133: Removing The Distillation Flask And Expansion Tank

    Distillation Process Analyzer DPA-4.5 Maintenance Removing the distillation flask and expansion tank • Open the plug connections 1–3: Figure 10.1: Unplugging the distillation flask heater and temperature sensor December 2013...
  • Page 134 Distillation Process Analyzer DPA-4.5 Maintenance Removing the distillation flask expansion tank • Mark the bolt connections with a felt-tip pen to ensure that they are reassembled correctly. • Use another wrench to hold the other side of the bolt connections.
  • Page 135 Distillation Process Analyzer DPA-4.5 Maintenance Removing the distillation flask • Mark the bolt connections with a felt-tip pen to ensure that they are reassembled correctly. • Use another wrench to hold the other side of the bolt connections. • Remove bolts 1–5 in order.

  • Page 136: Cleaning The Distillation Flask And Bubble Pipe

    Distillation Process Analyzer DPA-4.5 Maintenance Cleaning the distillation flask and bubble pipe • Undo the bolt (1), holding another wrench on the other side (2). Cleaning the distillation flask • Take off the upper section (3). • Clean the inside of the distillation flask through the opening at the top.

  • Page 137: Installing The Distillation Flask And Expansion Tank

    Distillation Process Analyzer DPA-4.5 Maintenance • Clamp the 1.5 mm drill bit in the appropriate chuck Cleaning the bubble pipe (see page 127). • Insert the drill bit into the bubble pipe and turn the bit while pushing it back and forth.
  • Page 138 Distillation Process Analyzer DPA-4.5 Maintenance Installing the distillation flask • Carefully put the distillation flask back in, so that all the bolts are lined up and the cables are laid correctly. • Only hand-tighten the bolts (1) to (6) at first. It should be possible to put in the distillation flask without any major strain.
  • Page 139 Distillation Process Analyzer DPA-4.5 Maintenance Installing the distillation flask expansion tank • Carefully put the expansion tank back in the correct position (see the illustration below). • Only hand-tighten the bolt (1) at first. • Using another wrench as a counterhold, tighten the bolts until the markings line up.
  • Page 140 Distillation Process Analyzer DPA-4.5 Maintenance Restoring the plug connections • Plug the connectors 1–3 back together. Figure 10.10: Plugging in the distillation flask heater and temperature sensor • Close the measuring unit box. • Restarting operation For the steps to be taken after maintenance work, please refer to page 151.

  • Page 141: Cleaning The Flame Arresters

    Distillation Process Analyzer DPA-4.5 Maintenance 10.5.6 Cleaning the flame arresters All supply and drain lines to and from non-failsafe pipeline systems in the Ex d box are equipped with flame arresters (see page 62). The box provides explosion pressure for the measuring unit by the pressure-resistant enclosure ignition protection Ex d (see page 29) only in combination with the flame arresters.
  • Page 142 Distillation Process Analyzer DPA-4.5 Maintenance Overview Flame filter right (R) Outer box Flame filter left (L) O-ring Ribbed ring Inner box Figure 10.3: Flame arrester design. Three flame filters are installed. The middle flame filter (4) is equipped with gaps with a right-hand angular offset, and the two other flame filters (2) are equipped with gaps with a left-hand angular offset.
  • Page 143 Distillation Process Analyzer DPA-4.5 Maintenance Removing the flame arresters To clean the flame arrester, unscrew the inner box (7) from of the outer box (1). The outer box remains firmly screwed onto the Ex d box. • Disconnect the flame arrester from the pipeline. To do this, unscrew the Swagelok screw connection and the screw pipe connection on the inner box of the flame arrester.
  • Page 144 − The flame filter has become loose and the strips of the filter disc can be moved easily. New flame filters can be obtained from BARTEC BENKE. To order them, information on the filter gap width, the material and the angular offset of the gap in the flame filter (right = R, left = L) are required.
  • Page 145 Distillation Process Analyzer DPA-4.5 Maintenance Assembling the flame arresters WARNING Danger of explosions due to incorrectly mounted flame arresters The Ex d box does not provide any explosion protection if the flame arresters are mounted incorrectly. For this reason: – Make sure that all three flame filters are in use.

  • Page 146: Replacing The Heating Cartridges And/Or Flask Bottom Temperature Sensor

    Distillation Process Analyzer DPA-4.5 Maintenance 10.5.7 Replacing the heating cartridges and/or flask bottom temperature sensor If one heating cartridge is defective, the whole set has to be replaced. The heating cartridges are easier to remove if the flask bottom temperature sensor is removed first. If this is also defective, you can replace it at the same time.
  • Page 147 Distillation Process Analyzer DPA-4.5 Maintenance Removing the flask bottom temperature sensor Figure 10.12: Loosening the flask bottom temperature sensor holder • Undo the screw (1) of the flask bottom temperature sensor holder. Figure 10.13: Removing the flask bottom temperature sensor •...
  • Page 148 Distillation Process Analyzer DPA-4.5 Maintenance • Undo the screws of the holder (1) until it is loose. Removing the heating cartridges • Pull out the heating cartridges. Do not pull the cable. Figure 10.14: Loosening the heating cartridge holder In some cases the heating rods may be stuck so tight in their holes that they cannot be pulled out.

  • Page 149: Replacing The Battery Of The Industry Pc

    Distillation Process Analyzer DPA-4.5 Maintenance Installing the heating cartridges This is how to install the heating cartridges again. • Thoroughly clean the holes in the bottom of the flask. • Insert the heating cartridges in the holder. • Make sure the holder is installed in the right position. The fastening hole must be at the bottom.
  • Page 150 Distillation Process Analyzer DPA-4.5 Maintenance • Open the control box (see page 27). Batteries WARNING Risk of explosion if unsuitable batteries are used Unsuitable batteries may overheat in the event of a fault and ignite potentially explosive atmospheres. Therefore: – Always only use replacement batteries from BARTEC BENKE.

  • Page 151: Measures After Maintenance

    Distillation Process Analyzer DPA-4.5 Maintenance 10.6 Measures after maintenance After completion of the maintenance work and before switching on, carry out the following: • Check that all previously loosened screw connections have a tight fit. • Make sure that all previously removed protective devices and covers have been properly reinstalled.

  • Page 152: Dismantling

    Distillation Process Analyzer DPA-4.5 Dismantling 11 Dismantling At the end of its service life, the device must be dismantled and disposed of in an environmentally friendly manner. 11.1 Safety − Dismantling is only to be performed by specialists for Personnel potentially explosive atmospheres.

  • Page 153: Preparations For Dismantling

    Distillation Process Analyzer DPA-4.5 Dismantling 11.2 Preparations for dismantling • Clean the device prior to disposal. • Empty product-conveying components. • Switch off the device and secure it against being switched on again. • Discharge stored residual energy. • Remove operating and auxiliary materials as well as any other processing materials and dispose of them in an environmentally friendly manner.

  • Page 154: Disconnecting Pipe Connections

    Distillation Process Analyzer DPA-4.5 Dismantling • Disconnecting electrical Disconnect the device completely from the power supply. connections • Secure it against being switched on again. • Open the junction box. • Disconnect all cables from the terminals and pull them out of the junction box.
  • Page 155 Distillation Process Analyzer DPA-4.5 Dismantling • Disconnecting pipe connections Check that the pressure has been fully released. • Collect any residual materials that may emerge separately. • Disconnect the pipe connections in accordance with the installation plan in the customer folder.

  • Page 156: Disposal

    Distillation Process Analyzer DPA-4.5 Dismantling 11.5 Disposal Device Disassemble the device in accordance with the pertinent work safety and environmental protection guidelines. Make the disassembled components available for recycling: − Have metals scrapped. − Make plastic elements available for recycling.
  • Page 157 Distillation Process Analyzer DPA-4.5 Index 12 Index Fault table ............118 ASTM D 86 ............61 Faults ..............113 cooling pipe temperature ........ 70 FBP ............47, 60, 61 distillation groups ..........61 Fill level ...............60 inlet temperature ..........49 Final boiling point ..........60 ATEX marking ............
  • Page 158 Distillation Process Analyzer DPA-4.5 Index Safety equipment Operating conditions .......... 55 commissioning ..........103 Operating elements ........... 73 faults ............. 113 Operating manual ..........8 general ............43 Operation ............108 installation ............83 Operator ............. 12 maintenance ..........122 Overview ............58 Safety gloves hazardous substances ........

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