pgc6000_manual_en_01 by neue formen GmbH & Co. KG

Process Gas Chromatograph PGC 6000

OPERATING INSTRUCTIONS

Serving the Gas Industry Worldwide

STATUS NOVEMBER 2009

by Honeywell

...............................................................................................................................................................................................................

Note: Unfortunately, paperwork does not automatically update itself but technical developments are constantly being made. Therefore, we reserve the right to change the descriptions and statements contained in our operating instructions without prior notice. However, you can conveniently download the most recent version of this manual (and those of other devices) from our website www.rmg.com.

RMG Messtechnik GmbH Otto-Hahn-Str. 5 35510 Butzbach (Germany) Fax: +49 (0)6033 897-130 E-mail: Messtechnik@Honeywell.com

Phone numbers: Switchboard: +49 (0)6033 897-0 Customer Service: +49 (0)6033 897-127 Spare Parts: +49 (0)6033 897-173

CONTENTS

INTRODUCTION ................................................................................... 1 CONSTRUCTION AND FUNCTION ...................................................... 2 Configuration of the overall system ..................................................................... 2 Measuring element with gas distribution ............................................................ 3 ERZ 2000 GC control computer............................................................................ 5

SAFETY INSTRUCTIONS ....................................................................... 6 INSTALLATION .................................................................................... 7 Requirements for the measuring room ................................................................ 7 Gas connections.................................................................................................... 7 Pipes and connections .................................................................................................. 7 Carrier gas..................................................................................................................... 8 Calibration gas .............................................................................................................. 8 Outlet pipes ................................................................................................................... 9

Electrical connections .......................................................................................... 9 Explosion protection ...................................................................................................... 9 Connection box in the casing of the measuring element ............................................. 10 Terminal assignments.................................................................................................. 10

START-UP .......................................................................................... 11 Adjusting the inlet pressures .............................................................................11 Purging the supply lines and the measuring element .......................................11 Purging the piping ....................................................................................................... 11 Purging the measuring element ................................................................................... 12

Switching on the measuring element.................................................................12

OPERATION ....................................................................................... 13 How to operate the PGC 6000 ...........................................................................13 Manually initiating calibration runs ....................................................................13 Putting the PGC 6000 out of operation ..............................................................13

MAINTENANCE .................................................................................. 14 Changing the cylinders .......................................................................................14 Follow-up verification .........................................................................................14

TECHNICAL DATA.............................................................................. 15

CONTENTS

ANNEX ............................................................................................... 16 Assembly instructions for Swagelok fittings .....................................................16 EC type examination certificates .......................................................................17

INTRODUCTION

Introduction Natural gas is billed on the basis of the energy it contains and not on the basis of the gas volume sold. For this purpose, it is necessary to know the composition of the relevant gas in order to be able to calculate the superior calorific value and thus, the energy content. In order to be able to calculate the gas law deviation coefficient (K coefficient), it is also necessary to know the gas quality.

A gas chromatograph can determine the composition of the relevant natural gas within a short time and at low operating costs. For this purpose, the sample gas is passed together with a carrier gas through capillaries, which are called separating columns. Since the various gas components are retained at the lining of the separating columns due to different adsorptive forces, they arrive at the end of the separating columns at different times. Here a thermal conductivity detector detects the components coming out of the separating columns and supplies signals from which the substance amount fraction of the component concerned can be determined. The PGC 6000 comprises the measuring element, which includes the chromatograph, and the ERZ 2000 GC control computer. The three separating columns of the measuring element enable the eleven most important natural gas components to be measured. In the measuring element the superior calorific value, standard density, Wobbe index and relative density are already calculated from the values measured. The control computer, among other things, displays the measuring results, controls automatic calibration runs and monitors the measuring element. The ERZ 2000 GC control computer is an RMG flow computer from the ERZ 2000 series in which a communication module has been installed. Thus, the flow computer comprises the functions of a PGC control computer and a gas volume corrector.

CONSTRUCTION AND FUNCTION

Construction and function Configuration of the overall system

The overall system of the PGC 6000 process gas chromatograph consists of the following components: - Measuring element with gas distribution (standard) - Control computer (standard) - Sampling probe (optional) - Pressure reducer (optional) - Carrier and calibration gas cylinders (to be provided by the operator)

PGC 6000

Gas distribution

Measuring element

GC 6000

7 2

1.) 2.) 3.) 4.) 5.) 6.) 7.) 8.)

Measuring gas

9.) 10.) 11.)

Sampling probe Pressure reducer Measuring unit Measuring element Inlet 2 for two-stream version GC 6000 analytical computer Press. reducing unit (measuring gas/ calibration gases) Press. reducing unit (calibration gases/ carrier gas) Internal calibration gas, 10 External calibration gas, 10 Carrier gas (helium), 10

CONSTRUCTION AND FUNCTION

Measuring element with gas distribution 612 mm 516 mm E1

280 mm

3 ventilation

fixing hole ø11

ventilation

K1 A B C M1 M2

Gas inlets: A. carrier gas (inlet pressure 4.5 bar) B. int. calibration gas (inlet pressure 2-3 bar) C. ext. test gas (inlet pressure 2-3 bar) M. measuring gases (inlet pressure 2-3 bar)

All tube fittings and connections in Swagelok system, tube diameters for the connections: A, B, C: 1/8” M1, M2: 4 mm K1, K2: 6 mm E1, E2: 12 mm

2-stream (option) 1-stream (standard)

Gas outlets: E1. vent line of bypass E2. vent line of measuring gas K1+K2. condensate outlet

1.) isolation cabinet with window in cover 2.) liquid separator for measuring gas 3.) pressure reducer for carrier gas 4.) pressure reducer for measuring gas 5.) flowmeter for bypass of measuring gas 1+2 6.) flowmeter for measuring gas 7.) solenoid valve block 8.) measuring element CP 6000 9.) heater 100 W with 10°C fixed value thermostat in the connecting cable 10.) EEx (e) connection box for pos. 7, 8, 9

CONSTRUCTION AND FUNCTION

In the casing besides the measuring element there are also the following items: - Casing heating with thermostat. The heating has been approved for areas subject to explosion hazards and is to be supplied with 230 VAC; its temperature has been permanently set at 10掳C.

- Valve block for switching automatically between sample, calibration and test gases. Every inlet which is not connected is shut off by two valves so that even in the case of a leakage the gases will not mix. The intrinsically safe solenoid valves are controlled by the ERZ 2000 GC control computer. - Condensate separator. The condensate is separated on a membrane and can be drained through a valve at the bottom of the casing. The membrane acts as a gas filter at the same time. - Pressure-reducing units for sample and carrier gases. Here the inlet pressure for the measuring element is fine adjusted. - Bypass pipe for sample gas with a variable area flowmeter and an adjustment valve. Since only a small quantity of gas flows through the measuring element due to miniaturisation, sample gas is directed past the measuring element to the exhaust air in order to increase the flow rate in the supply pipe. This ensures that current sample gas is analyzed in each case. The standard version of the PGC 6000 has been designed for measuring gas from one tapping point (single stream design). This version has been approved for custody transfer metering. For secondary metering, the PGC 6000 may be designed as a 2-stream unit.

CONSTRUCTION AND FUNCTION

ERZ 2000 GC control computer

MESSTECHNIK

Flow computer ERZ 2004 Ser.-No.:

7.741 04.56

Year:

Dry gas in standard condition (1.01325 bar, 0°C) Right at =0 Further data press button "ID"

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The ERZ 2000 GC control computer comprises a flow computer from the ERZ 2000 series plus an expansion module for controlling valves and communicating with the measuring element. The ERZ 2000 can be used as a control computer from software version 1.7 upwards. Thus, the correction function is available for a gas meter at the same time. With this configuration, it is not possible to use an internal isolating card for the volume measurement inputs. For a description of the control computer and its operation, please refer to the "ERZ 2000" manual. Here all parameters and operating modes for the PGC 6000 are described.

SAFETY INSTRUCTIONS

Safety instructions The PGC 6000 process gas chromatograph is used to measure the composition of natural gases and determine the superior calorific value and standard density. Damage may be caused to the chromatograph if other gases are passed through the measuring element. 6

The PGC 6000 complies with the currently applicable standards and regulations. However, failure to operate it properly may cause hazards. Persons who install or operate a PGC 6000 process gas chromatograph in an area subject to explosion hazards must be familiar with the currently applicable explosion protection standards and regulations. Please follow the instructions below: Danger of explosion In the manual, this symbol warns you of an explosion hazard. Please follow the instructions given next to this symbol. The PGC 6000 process gas chromatograph has been approved for use in areas subject to explosion hazards. Any modifications of the device, in particular installation of components, may result in this approval becoming void. Please make sure that you comply in particular with the instructions regarding the electrical connection of the PGC 6000. Damage to property In the manual, this symbol warns you of possible damage to property. The instructions given next to this symbol inform you about what you can do to avoid damage to the PGC 6000 process gas chromatograph. It is essential to observe the warning information in these operating instructions and the generally applicable safety rules. No warranty claims can be asserted if there is unauthorized interference with the device!

INSTALLATION

Installation Requirements for the measuring room In Germany, the place where the PGC 6000 is to be installed has to comply with PTB's requirements PTB-A 7.62 for superior calorific value measuring devices. The most important requirements are as follows: ● ● ● ●

The PGC 6000 is to be installed in a clean and dry room which is sufficiently isolated and protected against direct sunlight and climatic influences. The PGC 6000 may not be exposed to draughts. The room size has to be at least 9 m². If more than one process gas chromatograph is to be installed in a room, there has to be a minimum floor area of 6 m² for each additional device. Room temperature must be between -10°C and 55°C all year round. The difference between the highest and lowest room temperatures may not exceed 5°C within a period of 24 hrs. It is recommended that a mean room temperature of 23°C be reached. The room temperature has to be continuously monitored using min/max thermometers, for example. The control computer has contact inputs which can be used for this purpose.

Gas connections Pipes and connections Stainless steel pipes must be used for all lines (sample gas, calibration gas and carrier gas); these pipes have to be gas-tight in the relevant pressure range. Make sure that the pipes are free from dirt, grease and solvents. The gas connections of all components are equipped with Swagelok fittings. Please follow the assembly instructions for Swagelok fittings in the annex. Never retighten already assembled Swagelok connections, otherwise they may become leaky. In order to ensure proper analyses to be performed, all connections have to be tight to prevent contamination with air. If it is necessary to seal threads or fittings, use only Teflon tape. Helium is volatile and escapes even through small leaks; thus, it is essential to carefully seal and check the system. Do not use any liquid leak detector, since such agents may contaminate the separating columns.

INSTALLATION

Carrier gas Helium which is used as carrier gas has to comply with class 5.0 (purity: 99.999%). We recommend that a vent valve be installed at the inlet of the measuring element to protect the device when the cylinder is replaced. Connection is to be made through ⅛" piping.

A full 10 or 50 litre cylinder with 200 bar will be sufficient for approx. 25 or 125 days respectively. Should the cylinder be empty much earlier than that, this indicates a leak in the piping. In order to increase operational safety, we recommend that 50 litre cylinders be used. After the helium cylinder has been connected and prior to switching on the power supply, purge the helium pipe to the measuring element in accordance with the instructions in chapter "Start-up"!

Calibration gas In Germany, the composition of the calibration gas to be used for custody transfer metering is specified as per the table below. When the device is used in other countries, the applicable national rules and regulations have to be complied with. If there are no such rules and regulations or in the case of secondary metering, the gas composition may deviate from the specified one but we recommend using the composition below nevertheless. Component Nitrogen Methane Carbon dioxide Ethane Propane Isobutane n-Butane Neopentane Isopentane n-Pentane n-Hexane

Concentration (mol%) 4.00 88.90 1.50 4.00 1.00 0.20 0.20 0.05 0.05 0.05 0.05

Please also note the instructions and specifications stated on the certificate of the calibration gas. Particular care must be taken to ensure that the calibration gas cylinder is kept in a frost-free location, since segregation may occur at low temperatures. If a calibration gas cylinder has once cooled below 0°C, it must not be used any longer. There is no statutory regulation for test gas. However, it is also a gas mixture which has to be stored and installed at temperatures above 0°C. Calibration gas or test gas is to be connected via ⅛" piping. ............................................................................................................................................................................................................... Manual PGC 6000 · EN01 · 2009-11

INSTALLATION

Outlet pipes The outlet pipes of the measuring element and the bypass are to be directed separately to the outside as 12 mm piping without constriction. If these two pipes are brought together, this would result in a higher pressure at the outlet of the measuring element which would in turn cause an error in measurement. Apart from that, further devices must not be connected to the outlet pipe of the measuring element. 9

Electrical connections Explosion protection The solenoid valves for switching between sample gas, calibration gas and carrier gas are intrinsically safe and may only be connected to certified intrinsically safe circuits. This means that several isolating amplifiers have to be installed between the measuring element and the control computer in accordance with the number of solenoid valves fitted (see drawing).

MESSTECHNIK

Alarm

Flow Computer Type ERZ 2004 Ser.-No.: Year:

Sample gas

Dry gas in standard condition (1.01325 bar, 0°C) Right at =0 Further data press button "ID”

Calibration gas

Test gas

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Meas.P,T..

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Pressure Temperature

Measuring element

Isolating device for volume pulses

Volume

Valve block Isolating devices

INSTALLATION

Connection box in the casing of the measuring element

9 10 11 12 13 14 15 16

17 18 19 20 21 PE PE 22 PE

9 10 11 12 13 14 15 16

17 18 19 20 21 PE PE 22 PE

Intrinsically safe connections of the solenoid valves

Power supply and data line

Terminal assignments Terminal of the measuring element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Terminal of the isolating amplifier Module 1: 1 ↔ 11 Module 1: 4 ↔ 14 Module 1: 2 ↔ 12 Module 1: 5 ↔ 15 Module 2: 1 ↔ 11 Module 2: 4 ↔ 14 Module 2: 2 ↔ 12 Module 2: 5 ↔ 15 Module 3: 1 ↔ 11 Module 3: 4 ↔ 14 Direct connection Direct connection

Terminal of the control computer X9 – 1 X9 – 2 X9 – 3 X9 – 4 X9 – 5 X9 – 6 X9 – 7 X9 – 8 X9 – 9 X9 – 10

L N + X10 – 8 X10 – 7

START-UP

Start-up Adjusting the inlet pressures The casing of the PGC 6000 accommodates two pressure regulators for fine adjustment of the inlet pressures of the carrier and sample gases. The actual pressure reduction has to be performed upstream. The inlet pressure must never exceed 10 bar(g) to avoid damage to the measuring element.

Carrier gas: The pressure of the carrier gas is to be adjusted with the left regulator (item 3 of drawing on page 3). The specified value is 4.5 bar ±10%. Sample gas: The pressure of the sample gas, calibration gas or test gas is to be adjusted with the left regulator (item 4 of drawing on page 3). The permissible pressure is 2 - 3 bar. Normally, the optimum sample gas pressure has already been adjusted in the factory.

Purging the supply lines and the measuring element Power supply of the PGC 6000 must not be switched on until the carrier gas pipe and the measuring element have been purged in accordance with the instructions below. High concentrations of oxygen will result in the destruction of the measuring element. Helium constantly flows through the measuring element; in addition to its function as carrier gas, it also protects the measuring element. The measuring element is only protected against atmospheric oxygen if helium flows through it. Oxygen contents in the sample, calibration and test gases do not pose a risk to the measuring element since only substantially smaller quantities of oxygen are involved here. In order to avoid any adverse effects on the accuracy of measurement, the supply lines of these gases are to be purged as well.

Purging the piping In order to ensure that the piping is sufficiently purged irrespective of the length of the supply lines, follow the procedure described below: ● Open the cylinder valve and leave it open until the pressure in the carrier gas line does not increase any more. ● Close the cylinder valve. ● Loosen the fitting at the carrier gas inlet of the measuring element. ● Allow the carrier gas to escape and wait until the supply line is depressurized. ● Then retighten the fitting. ● Repeat this purging procedure four times. ............................................................................................................................................................................................................... Manual PGC 6000 · EN01 · 2009-11

START-UP

Purging the measuring element After you have purged the piping, you still have to purge the measuring element to evacuate the air. For this purpose, helium has to flow for at least one hour through the measuring element which has to be switched off during this time. Do not switch on the power supply of the measuring element until this period has elapsed. 12

Switching on the measuring element If all supply lines have been purged, the power supply of the measuring element can be switched on. Check whether the heating of the measuring element is also powered. The PGC 6000 starts with a calibration run which will last for approx. 40 minutes. On the initial start-up, there may still be traces of air in the piping. These traces are harmless but may result in a failure of the first calibration run. This can be seen from the fact that the nitrogen content measured during the calibration gas analysis is considerably higher than its specified value. In this case, the PGC 6000 performs another calibration run. If the second calibration run is not successful either, an alarm message will be outputted.

OPERATION

Operation How to operate the PGC 6000 The PGC 6000 is mainly operated through the ERZ 2000 GC control computer. The latter displays the measuring results and here you can also choose the gas to be measured (sample gas, calibration gas or test gas). For further details concerning the operation of the control computer and the meaning of the individual parameters, please refer to the ERZ 2000 manual which is provided.

For operation, the following points should be observed: ● The PGC 6000 performs automatic calibration runs at regular intervals. In Germany, one calibration run per day is specified for custody transfer metering. The time of the calibration run can be set; the duration of a calibration run is approx. 40 minutes. ● Every hour at least four analyses are to be performed for each gas stream.

Manually initiating calibration runs A calibration run can be manually initiated even outside the automatic calibration interval. Calibration runs can be initiated by jumpering inputs X8-1 and X8-2 of the ERZ 2000 GC. Some versions have a "Calibrate" pushbutton on the signalling module for this purpose. LEDs of the signalling and calibration module indicate whether the measuring element is analyzing sample gas, calibration gas or test gas. Another way to perform a calibration manually is to use the arrow keys at the display of the ERZ 2000 GC to move to coordinate IL-11 and then to press the Enter key to start the calibration.

Putting the PGC 6000 out of operation If the PGC 6000 is put out of operation only for a short time, it is advisable to maintain the helium flow. Should you put the PGC 6000 out of operation for a prolonged period, switch of the power supply of the measuring element before you cut the helium supply. If there is no helium flow, air may enter the measuring element through the outlet pipe. Prior to another start-up, the measuring element has to be purged again for at least one hour!

MAINTENANCE

Maintenance Changing the cylinders

When you change the helium cylinder, it is essential to make sure that no air enters the carrier gas line! Every helium line which was opened has to be purged before another start-up can be made. To change the cylinder, proceed as follows: 1. Close the cylinder valve of the empty cylinder. 2. Close the inlet valve of the measuring element (inlet A of drawing on page 3). 3. Screw off the connection fitting from the empty cylinder and screw it on the full cylinder. 4. Open the cylinder valve. 5. If the pressure in the helium pipe does not increase any more, close the cylinder valve. 6. Unscrew the fitting at the inlet of the measuring element and blow off helium. 7. Tighten the fitting. 8. Repeat steps 4 to 7 for another 4 times. 9. Open the inlet valve of the measuring unit. 10. Check the inlet pressure at the inlet pressure regulator and, if necessary, increase or decrease the pressure to 4.5 bar. If there is another valve upstream of the measuring element, you can also use this valve to shut off and vent the line. But you can also use an existing vent valve instead of opening the fittings (recommended procedure). IMPORTANT: Venting has to be carried out at the location of the valve and not in the middle of the piping. The period of use of a calibration gas cylinder for custody transfer metering is limited. Please note the information stated on the certificate of the calibration gas cylinder.

Follow-up verification Depending on statutory regulations applicable at the place of use of the PGC 6000, the latter has to be subjected to follow-up verification at regular intervals. In Germany, the follow-up verification interval is one year.

TECHNICAL DATA

Technical data Casing Material Dimensions

Polyester W x H x D = 516 x 900 x 280 mm

Operating conditions Ambient temperature range Humidity

-10°C to 50°C 0 to 95% relative humidity

Power supply Measuring element Control computer

24 VDC 230 VAC 24 VDC or 230 VAC

Power input Measuring element Heating of measuring unit Control computer

50 W 100 W 24 W

Inlet pressures Carrier gas Sample gas Calibration gas/test gas

4.5 bar 2 to 3 bar 2 to 3 bar

Carrier gas (helium) Purity Consumption

5.0 50 ml/min

Sample gas Humidity Consumption

less than 2000 ppm 50 ml/min

Operating ranges Superior calorific value Standard density

7.0 to 14 kWh/m³ 0.7 to 1.0 kg/m³

ANNEX

Annex Assembly instructions for Swagelok fittings INITIAL INSTALLATION 16

Cut the tubing perpendicularly and remove the fins. Insert the tubing into the tube fitting. Make sure that the tubing rests firmly on the shoulder of the tube fitting body and that the nut is finger-tight.

Before tightening the SWAGELOK nut, scribe the nut at the 6 o'clock position.

Then tighten the nut 1¼ turns* until the scribe mark reaches the 9 o'clock position. * For 2, 3, 4 mm or 1/16", 1/8", 3/16" tube fittings, tighten the nut ¾ turn on initial installation.

RETIGHTENING INSTRUCTIONS Fitting shown in the disconnected position. Insert tubing with pre-set ferrules into the fitting body until the front ferrule seats. Tighten the nut by hand. Then tighten the nut approx. ¼ turn with a wrench.

ANNEX

EC type examination certificates Evidence of explosion protection of the PGC 6000 process gas chromatograph is provided by the EC type examination certificates (in accordance with Directive 94/9/EC) of the individual components: Measuring element: EC type examination certificate: ISSeP 01 ATEX 003 X Type of protection: II 2 GD EEx d IIC T6

Solenoid valves: EC type examination certificate: PTB 01 ATEX 2175 Type of protection: II 2 G EEx ia IIC T6 and EEx ia IIC T5 Casing heating: EC type examination certificate: PTB 02 ATEX 1041 X Type of protection: II 2 G EEx d IIC or dm IIC T6, T5, T4, T3 Connection box: EC type examination certificate: KEMA 00 ATEX 8501 X Type of protection: II 2 G EEx e II T6 or II 1 G EEx ia II T6 or II 2(1) G EEx e (ia) IIC T6 Cable feedthroughs: EC type examination certificate: LCIE 97 ATEX 6005 X Type of protection: II 2 GD EEx e II Isolating device: EC type examination certificate: CESI 02 ATEX 086 Type of protection: II (1) G [EEx ia] IIC