Pgc9300 cp4900 manual en 01

PGC 9300 – Measuring Element

OPERATING INSTRUCTIONS

Serving the Gas Industry Worldwide

STATUS SEPTEMBER 2013

by Honeywell

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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

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Manual PGC 9300 路 EN03 路 2013-09

CONTENTS

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1 MEASURING PRINCIPLE ................................................................................ 1 2 CONSTRUCTION OF THE MEASURING ELEMENT......................................... 4 2.1 Gas distribution (Figure 2.2) ......................................................................................... 6 2.2 The gas chromatograph ................................................................................................ 6

3 FUNCTIONAL DESCRIPTION........................................................................ 10 3.1 Sequence of analysis .................................................................................................. 10 3.2 Separating columns .................................................................................................... 15

4 DATA ACQUISITION AND EVALUATION GAS CHROMATOGRAPH ............. 16 4.1 Fundamentals .............................................................................................................. 16 4.1.1 4.1.2

Fundamentals of analysis .............................................................................................. 16 Fundamentals of evaluation ........................................................................................... 17

4.2 Calibration in the factory ............................................................................................ 18 4.3 Basic calibration .......................................................................................................... 18 4.4 Recalibration ............................................................................................................... 19

5 REQUIREMENTS FOR GASES USED / GAS CONSUMPTION ...................... 20 5.1 Carrier gas ................................................................................................................... 20 5.2 Internal calibration gas ............................................................................................... 20 5.3 Measuring gas ............................................................................................................. 21

6 CONNECTION AND STARTUP ...................................................................... 22 6.1 Electrical connections ................................................................................................. 22 6.2 Gas connections .......................................................................................................... 23 6.2.1 6.2.2

Carrier gas connection .................................................................................................. 23 Measuring gas / calibration gas / reference gas........................................................... 24

6.3 Column pressure and temperature ............................................................................ 24 6.4 Further action .............................................................................................................. 24 6.5 Interruption of carrier gas supply ............................................................................... 25

7 OPERATING MODES OF THE MEASURING ELEMENT ................................. 26 7.1 Automatic analytical mode / AUTORUN .................................................................... 26 7.2 Stop mode ................................................................................................................... 26 7.3 Manual calibration ...................................................................................................... 26

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Manual PGC 9300 · EN03 · 2013-09

CONTENTS

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7.4 Reference gas analysis ............................................................................................... 26 7.5 Basic calibration .......................................................................................................... 26

8 OPERATING INSTRUCTIONS FOR THE EXPLOSION-PROTECTED DESIGN......................................................................................................... 27 8.1 General instructions .................................................................................................... 27 8.2 Explosion-proof enclosure .......................................................................................... 27 8.3 Increased-safety terminal compartment .................................................................... 27 8.4 Maintenance ................................................................................................................ 28 8.5 Safety measures.......................................................................................................... 28 8.6 Maintenance Work ...................................................................................................... 28 8.7 Repairs ......................................................................................................................... 28

9 FAULT MESSAGES ....................................................................................... 29 9.1 Faults occurring during continuous analytical operation .......................................... 29 9.2 Faults occurring during recalibration ......................................................................... 30 9.3 Power failure of the GC 9300 ..................................................................................... 30

10 DATA STORAGE / PRINT REPORTS ............................................................. 31 10.1 Data Storage................................................................................................................ 31 10.1.1 10.1.2

The general data logger ................................................................................................. 31 The fiscal metering data logger according to DSfG standard ......................................... 31

10.2 Print Reports ............................................................................................................... 32

11 INSPECTION AND MAINTENANCE WORK ................................................... 33 11.1 General instructions .................................................................................................... 33 11.2 Regular maintenance work ......................................................................................... 33 11.2.1 11.2.2 11.2.3

Draining condensate at the measuring element............................................................. 33 Exchanging carrier gas cylinder ..................................................................................... 33 Exchanging the carrier gas filter .................................................................................... 37

13 TECHNICAL DATA OF THE MEASURING ELEMENT .................................... 38

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Manual PGC 9300 · EN03 · 2013-09

1 MEASURING PRINCIPLE

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1 Measuring Principle A gas sample is taken from the process line by means of a sampling probe. In a gas preconditioning unit the sample is filtered and reduced in pressure before it is conducted into the measuring element.

Figure 1.1 shows the typical construction of the chromatograph in a block diagram.

1

In the gas distribution system (1) one of the three inlets is connected to the analyzer via a double block and bleed valve unit. A precisely defined quantity of gas to be analyzed is conducted to the separating columns by means of the injector.

This quantity is conducted through the separating columns representing the so-called mobile phase by means of a carrier gas.

The separation of the gas mixture is based on the reciprocal effect between the stationary phase, the packing or filling of the columns and the components of the gas flowing by. Due to the different reciprocal effect between the gas components and the stationary phase, the individual components are selectively delayed when they pass through the column, i.e. they pass through it at different speeds.

Therefore, all components appear at different times at the end of the column.

A thermal conductivity detector (TCD) records the components leaving the column. For each component a signal is generated which varies in length and height. This is a so-called peak. The area below the signal curve serves as a measure for the proportion in terms of quantity of the component involved.

Helium is used as carrier gas in the measuring element. Two or three columns which can be operated in parallel are used for gas separation.

The area proportions determined are evaluated in the GC 9300 analytical computer. There also the calculation of calorific value and standard density is carried out according to ISO 6976.

Depending on the factory calibration, a distinction is drawn between calorific value measuring devices, which determine superior calorific value, standard density and carbon dioxide contents for custody transfer metering (sufficient for the calculation of the compressibility factor according to GERG 88S) and gas quality measuring devices, where also the gas components are measured for custody transfer metering (required for AGA 8-92DC).

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Manual PGC 9300 路 EN03 路 2013-09

1 MEASURING PRINCIPLE

8 7

8

6. TCD 7. measured value 8. data preparing 9. vent line 2

13d

2

13c

13b

2

2

13a

12

2

2

11

10

2

P

1

P

3

column C

4

4 3

column B

1. gas stream selection system 2. gas filter 3. pressure reducer 4. injector 5. columns

5

5

6

6

7

8

6 5 4 3

column A

Functional Diagram Gas Chromatograph

7

2

10. carrier gas inlet 11. calibration gas inlet 12. test gas inlet 13. sample gas inlets (max. 4)

9

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Figure 1.1 ...............................................................................................................................................................................................................

Manual PGC 9300 路 EN03 路 2013-09

Manual PGC 9300 路 EN03 路 2013-09

2

1

hazardous area

X5 p sample gas (4-20 mA)

X5 / X6 p carrier gas (4-20 mA)

LAN1 GCI (control) Ethernet

X1 / X2 valve control

1. measuring element 2. terminal box 3. carrier gas inlet 4. calibration gas inlet 5. test gas inlet 6. sample gas inlets (max. 4) 7. vent outlet 8. control unit GC 9300

e.g. calibration/ measurement

contact output open collector

by Honeywell

non hazardous area

230 VAC / 24 VDC

3 4 5 6a 6b 6c 6d

24 VDC

7

10

GC 9300

X1 / X2

relay output alarm / warning

X4

PC

peripherals USB

COM5 - C7 Modbus RS 232

COM4 DSfG / RMG bus RS 232 / 485

COM3 DSfG / RMG bus RS 232 / 485

COM2 Wago add. I/Os RS 232 / 485

COM1 Modbus RS 232 / 485

LAN2 service Ethernet

communication ports

I4

I 2 current outputs I 3 0 / 4 - 20 mA

I1

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1 MEASURING PRINCIPLE

3

Figure 1.2

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2 CONSTRUCTION OF THE MEASURING ELEMENT

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2 Construction of the Measuring Element Figure 2.1 shows the measuring element in its explosion-proof ("Ex-d") design. The unit can be divided into four major constituents:

4

− The electrical connector box (2) with its connections to the GC 9300 analytical computer. (Data exchange, valve control, power supply) − An explosion-proof unit (1) comprising power supply and valve control components. − The gas distribution system with the carrier gas inlet A and the inlets for different gas streams (B, C, M1,...).

These inlets are connected to the chromatograph via a double block and bleed valve circuit.

Switching over is controlled via the GC 9300 analytical computer.

Furthermore, there a two pressure transducers monitoring the carrier gas pressure and the pressure of the gas to be analyzed. − The chromatograph itself in an explosion-proof enclosure (1).

This compact unit comprises separating columns, heating, injectors, detectors, pressure control system, data acquisition and communications hardware. The enclosure is heated in order to ensure that there is the required minimum internal temperature.

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Manual PGC 9300 · EN03 · 2013-09

2 CONSTRUCTION OF THE MEASURING ELEMENT

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Gas Chromatograph PGC 9300 Explosion protected design Outlet pipe bypass E1

E2 Outlet pipe sample gas 215

3

5 1

Gas inlets:

A. carrier gas 1 (inlet pressure 5.5 bar)

B. int. calibration gas (inlet pressure 2-3 bar)

2 1830

C. ext. test gas (inlet pressure 2-3 bar)

D. carrier gas 2

(inlet pressure 5.5 bar)

M. sample gases

(inlet pressure 2-3 bar)

4 A B C D

1-stream

3-stream

M1 M2

4-stream operation

M4

M3

Supply lines for connections A,B,C,D: 1/8“ pipe with clamping ring connection

5

6

465

2-stream

Supply lines for connections M1-4: 4 mm pipe with clamping ring connection Supply lines for connections E1, E2: 12 mm pipe with clamping ring connection

30

400

15

335

mounting hole Ø11 x 4

295 325

1.) Chromatograph, type CP4900-GC with valve controlexplosion-proof enclosure 2.) EEx(e) connection box 3.) Flow indicator for bypass, sample gas 4.) Gas inlet module from the left with filter plate in pipe (basic version)

Total weight: approx. 70kg

Option: 5.) Inlet filter carrier gas 1 for biogas usage 6.) Membrane filter unit with condensate collectors (hand valve) for sample gases

Figure 2.1 ...............................................................................................................................................................................................................

Manual PGC 9300 · EN03 · 2013-09

2 CONSTRUCTION OF THE MEASURING ELEMENT

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2.1

Gas distribution (Figure 2.2)

The gas distribution system serves to conduct one of the three gas streams to the analyzer and add the carrier gas.

In order to prevent any contamination of the selected gas stream by possible valve leakages, a double block and bleed valve configuration was chosen.

6

Figure 2.2 shows such a configuration with gas stream 2 being selected. It can be seen that the volumes between the valves of the unselected gas streams are open towards the atmosphere.

Therefore, leakages occurring cannot contaminate the gas stream to be analyzed.

2.2

The gas chromatograph

The figures 2.3 and 2.4 show the construction of the analyzing unit accommodated in an explosionproof enclosure (Figure 2.1, item 1).

The analyzing unit is comprised of three major functional units for each channel: − Pressure / valve control system This unit comprises the pressure control and monitoring system for the helium pressure before the columns as well as the control valves for the injector.

The setting is adjusted in the plant when basic calibration of the device is made. − Column modules Each column module is comprised of an injector, a reference column, a measuring column, thermal conductivity detectors, a column heating and if necessary backflush unit for column C (molecular sieve column). − Electronic unit This unit comprises the power supply, analog section, digital section and communications system.

Here data acquisition and preparation, temperature control and pressure monitoring as well as communication with the main board are performed.

The main board carries out the evaluation of the chromatogram and the transmission of all data to the analytical computer.

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Manual PGC 9300 · EN03 · 2013-09

2 CONSTRUCTION OF THE MEASURING ELEMENT

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Gas distribution

7

6 7

1

2

3

5

4

5

5

1. sample gas 2. calibration gas 3. test gas 4. safe shut off valve

5. gas filter 6. sample gas outlet 7. vent line

Figure 2.2

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Manual PGC 9300 路 EN03 路 2013-09

2 CONSTRUCTION OF THE MEASURING ELEMENT

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8

analysis modules

solenoid valve

pressure regulator pressure transmitter

Ex d case

Figure 2.3

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Manual PGC 9300 路 EN03 路 2013-09

2 CONSTRUCTION OF THE MEASURING ELEMENT

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analysis module main board

9

power supply

pressure regulator

column electronics Figure 2.4

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Manual PGC 9300 路 EN03 路 2013-09

3 FUNCTIONAL DESCRIPTION

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3 Functional Description 3.1

Sequence of analysis

The following five diagrams show the basic sequence of analysis. In order to facilitate understanding, the sequence is shown for one channel only.

10 - Initial position Carrier gas is connected to the injector at a pressure of 5.5 bar by means of a solenoid valve. It pressurizes the microvalves for injection and gas sampling which then shut. At the same time pressure-controlled carrier gas continuously flows through the flow resistors and the analytical and reference columns.

- Sweeping Set the solenoid valve for gas sampling to venting. The pressure at the microvalve is reduced and the valve opens. Then the gas stream sweeps the sample loop. The PGC 9300 is set to permanent sweeping is switched on permanently.

- Pressurization The solenoid sampling valve opens and pressurizes the microvalve for gas sampling with helium at a pressure of 5.5bar. The solenoid microvalve is closed and a defined sample gas volume is entrapped in the sample loop.

The solenoid valve pressurizes the sample loop with pressure-controlled carrier gas.

- Injection (30 ms - 255 ms) The solenoid injection valve switches to venting and opens the microvalve for injection. The pressure-controlled carrier gas of the solenoid valve forces the gas sample through the injection microvalve into the column. No sample gas is conducted to the reference column.

- Analysis The solenoid injection valve opens and pressurizes the injection microvalve which then shuts. The gas sample is separated in the column and passes the detector.

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Manual PGC 9300 路 EN03 路 2013-09

3 FUNCTIONAL DESCRIPTION

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SAMPLE IN SAMPLE

SAMPLE

CARRIER GAS REGULATED

CARRIER GAS 5.5bar SAMPLE VENT

PRESSURE REGULATOR

CARRIER GAS 5.5bar

PS

SWITCH

CARRIER GAS

SAMPLE LOOP

SAMPLE COLUMN SAMPLE

11 INJECTION

REFERENCE COLUMN INJECTION

TCD

Sweeping (initial position)

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Manual PGC 9300 路 EN03 路 2013-09

3 FUNCTIONAL DESCRIPTION

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SAMPLE

SAMPLE

CARRIER GAS REGULATED

CARRIER GAS 5.5bar SAMPLE VENT

PRESSURE REGULATOR

CARRIER GAS 5.5bar

PS

SWITCH

CARRIER GAS

SAMPLE LOOP

SAMPLE COLUMN SAMPLE

INJECTION

REFERENCE COLUMN INJECTION

TCD

12

SAMPLE IN

Pressurization

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Manual PGC 9300 路 EN03 路 2013-09

3 FUNCTIONAL DESCRIPTION

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SAMPLE IN SAMPLE

SAMPLE

CARRIER GAS REGULATED

CARRIER GAS 5.5bar SAMPLE VENT

PRESSURE REGULATOR

CARRIER GAS 5.5bar

PS

SWITCH

CARRIER GAS

SAMPLE LOOP

SAMPLE COLUMN SAMPLE

13 INJECTION

REFERENCE COLUMN INJECTION

TCD

Injection

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Manual PGC 9300 路 EN03 路 2013-09

3 FUNCTIONAL DESCRIPTION

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SAMPLE

SAMPLE

CARRIER GAS REGULATED

CARRIER GAS 5.5bar SAMPLE VENT

PRESSURE REGULATOR

CARRIER GAS 5.5bar

PS

SWITCH

CARRIER GAS

SAMPLE LOOP

SAMPLE COLUMN SAMPLE

INJECTION

REFERENCE COLUMN INJECTION

TCD

14

SAMPLE IN

Analysis

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Manual PGC 9300 路 EN03 路 2013-09

3 FUNCTIONAL DESCRIPTION

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3.2

Separating columns

As already mentioned above, two or three separating columns are operated in parallel in the measuring element. The three columns are: Channel A Typ: Haye Sep A 15

Channel B Typ: CP-Sil 5 CB Channel C Typ: Molecular sieve The sequence of analysis described under 3.1 equally applies to all channels.

The following different versions with two or three channels are available: Version Natural gas  PGC 9301 Biogas  PGC 9302 Natural gas extended  PGC 9303

Channels (column modules) A B A C A B C

Measured components N2, C1,CO2, C2 C3 to C6 C1, CO2, C2 to C4 H2, O2, N2 C1, CO2, C2 C3 to C6 H2, O2, N2

The chronological sequence of the components is the same as the order in the list.

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Manual PGC 9300 · EN03 · 2013-09

4 DATA ACQUISITION AND EVALUATION GAS CHROMATOGRAPH

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4 Data Acquisition and Evaluation Gas Chromatograph 4.1 16

Fundamentals

In order to achieve a good separation of elements when they pass through the columns, and make it possible to correctly determine peak areas, it is necessary to define several basic parameters.

These are of decisive importance for correct functioning of the device. They are set in the plant and cannot be accessed by the user.

The relevant set of parameters is called method. Some of these settings are displayed and monitored via the analytical computer.

4.1.1

Fundamentals of analysis

Specific physical fundamentals of the analytical procedure which directly affect the analytical result are determined in the method.

These are the following: - Column temperatures Column temperatures directly affect the separating capacity and duration of analysis. They are kept constant and are displayed on the analytical computer.

- Development time The development time determines the period during which data acquisition and evaluation of TCD signals are performed.

- Sweeping time This is the period during which the sample loops are swept with fresh measuring gas prior to injection. It is firmly preset in the factory.

- Carrier gas pressure Because the pneumatically controlled valves of the injector unit are operated by means of the carrier gas, a defined pressure (5.5 bar) is required. The setting is made via the inlet pressure regulation unit.

Monitoring of this pressure is also performed by the GC 9300.

It is not to be confused with the carrier gas pressure in the columns, which is separately adjusted at the chromatograph. ...............................................................................................................................................................................................................

Manual PGC 9300 路 EN03 路 2013-09

4 DATA ACQUISITION AND EVALUATION GAS CHROMATOGRAPH

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- Measuring gas pressure The measuring gas pressure is set to 1 bar in the factory. Once the precompression at the gas distribution system has been defined, it must be kept within a tolerance band. Measuring and monitoring are also performed by the analytical computer.

17

4.1.2

Fundamentals of evaluation

Specific parameters are given to evaluate voltage characteristics determined by the TCDs. Above all, a delimitation of element-specific peaks must be made.

The measuring element works on the principle of autogating, i.e. the relevant time gates are not firmly preset but determined according to the rise of the voltage characteristic. Within these time gates the area under the individual peaks is determined, which then is used for the calculation of the molar portions of the gas components.

The appropriate settings and expected retention times for the individual elements are defined by means of the method.

The latter are displayed on the analytical computer as RT for the current analysis runs and calibrations and as RTZ for the basic calibration.

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Manual PGC 9300 路 EN03 路 2013-09

4 DATA ACQUISITION AND EVALUATION GAS CHROMATOGRAPH

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4.2

18

Calibration in the factory

After a method has been defined and programmed, the first calibration of the device is made in the plant. It serves to assign peak areas to the corresponding proportions in terms of quantity of the components concerned. For this purpose, a number of calibration gases are used which contain the elements to be determined. The individual proportions in terms of quantity of the components involved cover the operating range.

After determination of the appropriate data record an approximation is made by a polynominal of 1st to max. 3rd order:

Concentration [n]  A  B  (area[n])  C  (area[n])2  D  (area[n])3 The values of the polynominal coefficients are stored in the GC 9300.

4.3

Basic calibration

During the initial start-up of the device a basic calibration is started at the analytical computer.

A calibration gas (internal calibration gas) with precisely defined composition is used. The corresponding concentrations of the components, as well as superior calorific value and standard density of the mixture are stored in the analytical computer.

A calibration cycle includes a selectable number of analyses of the calibration gas. Furthermore the number of analyses used for the averaging can be specified.

So for example it is possible to specify that in a calibration cycle 10 analyses are performed, where the last 5 are used for the averaging.

A concentration is calculated from the averaged peak areas for the respective component using the polynomial of the calibration in the factory.

Actual Concentration [n]  A  B  (area[n])  C  (area[n])2  D  (area[n])3 A response factor for the basic calibration is calculated using the stored specified concentrations.

RFZ [n] 

Specified concentration [n](%) Actual concentration [n](%)

Then the calculated concentration results in:

Concentration [n]  RFZ [n]  ( A  B  (area[n])  C  (area[n])2  D  (area[n])3 ) These factors are stored in the analytical computer and are compared with the values obtained in the recalibration (see 4.4).

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Manual PGC 9300 · EN03 · 2013-09

4 DATA ACQUISITION AND EVALUATION GAS CHROMATOGRAPH

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4.4

Recalibration

Automatic recalibration can be initiated by the analytical computer at certain intervals.

Apart from this, the user can initiate such recalibration by hand at any time.

Here also the internal calibration gas is used. The procedure corresponds to the basic calibration.

A concentration is calculated from the averaged peak areas for the respective component using the polynomial of the calibration in the factory.

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Actual Concentration [n]  A  B  (area[n])  C  (area[n])2  D  (area[n])3 A response factor is calculated using the stored specified concentrations.

RF [n] 

Specified concentrat ion [n](%) Actual concentrat ion [n](%)

Then the displayed concentration results in:

Concentration [n]RF[n]  ( A  B  ( Area[n])  C  ( Area[n])2  D  ( Area[n])3 ) These factors are used for calculating proportions in terms of quantity of the components involved until the next calibration is made. They are stored in the analytical computer.

As already mentioned above, new retention times (RT) which are compared with the original values from the basic calibration (RTZ) are determined each time recalibration is performed.

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Manual PGC 9300 · EN03 · 2013-09

5 REQUIREMENTS FOR GASES USED / GAS CONSUMPTION

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5 Requirements for Gases used / Gas Consumption 5.1 20

Carrier gas

Helium which is used as carrier gas must comply with class 5.0 (99.999%).

The inlet pressure must be PHe=5.5 bar (卤10%) to ensure correct functioning of the measuring element.

Pressure monitoring is carried out by a pressure transducer installed in the gas distribution system.

Its output signal is monitored by the GC 9000.

Helium consumption per column module is (depending on the column precompression selected) QHe= (4 - 10) ml/min Helium easily tends to leak out and, therefore, it is important to carefully seal off and monitor the system.

5.2

Internal calibration gas

The following composition is proposed for the internal calibration gas: Component

Nitrogen Methane Carbon dioxide Ethane Propane iso-Butane n-Butane neo-Pentane iso-Pentane n-Pentane n-Hexane Oxygen Hydrogen

Natural gas (type 11D) 4.00 88.90 1.50 4.00 1.00 0.20 0.20 0.05 0.05 0.05 0.05 0.00 0.00

Concentration (mol%) Biogas (type 9M) 4.00 89.00 2.50 2.50 1.00 0.20 0.20 0.00 0.00 0.00 0.00 0.40 0.20

Natural gas extended (type 12M) 4.00 87.45 1.50 4.00 1.00 0.20 0.20 0.00 0.05 0.05 0.05 0.50 1.00

For calorific value measuring devices five more calibration gases, near to the sample gas, are approved. Their composition is to be taken from the type approval. ...............................................................................................................................................................................................................

Manual PGC 9300 路 EN03 路 2013-09

5 REQUIREMENTS FOR GASES USED / GAS CONSUMPTION

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Calibration gases must not cool down below the permissible minimum temperature at any time. It can be found on the associated certificate. The usability of calibration gases is subject to a time limit, the expiration date is also provided in the certificate.

The inlet pressure is defined as pi = 1.0 bar It must already be determined prior to basic calibration. Any subsequent changes are not allowed.

Permissible deviations during operation are as follows:

21

dpi = 卤 10% During calibration gas is only consumed during the calibration time.

At a precompression of pi = 1.0 bar, there is a flow rate per column module of Q = 20 nml/min

5.3

Measuring gas

The sample to be analyzed must be in gaseous condition of aggregation and dry. Liquid components and other impurities are not permitted.

As to the inlet pressure and gas consumption, the values mentioned under 5.2 apply.

The operating ranges of the modules are within the following limits: Component

Nitrogen Methane Carbon dioxide Ethane Propane iso-Butane n-Butane neo-Pentane iso-Pentane n-Pentane C6+ Oxygen Hydrogen

Concentration (mol%) Custody transfer metering Secondary metering Natural gas Biogas Nat. gas ext. Natural gas Biogas Nat. gas ext.

0 - 20 0 - 20 0 - 20 0 - 20 0 - 20 0 - 20 65 - 100 70 - 100 65 - 100 65 - 100 65 - 100 65 - 100 0 - 10 0 - 8 0 - 10 0 - 12 0 - 12 0 - 12 0 - 15 0 - 14 0 - 15 0 - 20 0 - 20 0 - 20 0 - 5.5 0 - 9 0 - 9 0 - 10 0 - 10 0 - 10 0 - 4 0 - 4 0 - 4 0 - 5 0 - 5 0 - 5 0 - 4 0 - 4 0 - 4 0 - 5 0 - 5 0 - 5 0 - 0.1 0 - 0.1 0 - 0.1 to n-Butane* 0 - 0.12 0 - 0.12 0 - 0.3 0 - 0.3 0 - 0.12 0 - 0.12 0 - 0.3 0 - 0.3 0 - 0.3 0 - 0.3 0 - 0.3 0 - 0.3 0 - 5 0 - 5 0 - 5 0 - 5 0 - 5 0 - 5 0 - 5 0 - 5

*neo-Pentane is shown together with n-Butane as a sum.

Without column C, oxygen is recognized and shown together with nitrogen.

The limits are monitored by the analytical computer. For custody transfer metering the limiting values on the ID plate apply.

The extension of the measuring ranges for older devices to the table values above requires a new factory calibration. ...............................................................................................................................................................................................................

Manual PGC 9300 路 EN03 路 2013-09

6 CONNECTION AND STARTUP

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6 Connection and Startup 6.1

22

Electrical connections

The electrical connections must be made in compliance with the enclosed circuit manual for both the analytical computer and the measuring element. If no separate documentation for this purpose is available, the following pin assignment applies.

Attention: The power supply to the measuring element must not be made before the carrier gas flow has been ensured!

Pin assignment:

PE 2 6 10 14 18 22 PE 4 8 12 16 20 PE

23

PE 24

26 25

PE

PE 1 5 9 13 17 21 PE 3 7 11 15 19 PE

Range of the cable glands (permissible cable diameters): number

inner coating

outer coating

3

3.1 – 8.6 mm

6.0 – 13.4 mm

3

6.1 – 11.6 mm

9.5 – 15.9 mm

Meas. elem.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Signal p sample gas + p sample gas p carrier gas 1 + p carrier gas 1 TxD+ TxDRxD+ RxDp carrier gas 2 + p carrier gas 2 int. cal.gas ext. cal.gas stream 1 stream 2 stream 3 stream 4 GND

23 24 25 26

+ 24 V heater - 24 V heater + 24 V meas. elem.

- 24 V meas. elem.

GC 9300 X5 / 3 X5 / 4 X5 / 1 X5 / 2 X18 (X5 / 5) (X5 / 6) X2 / 1 X2 / 3 X1 / 1 X1 / 3 X1 / 5 X1 / 7 X1 / 2, 4, 6, 8 X2 / 2, 4

Ex-PGC

After switching on the analytical computer for the first time, certain parameters are set to specified values. These values should be monitored and changed, if necessary (see GC 9300 Operating Manual). The changed values will remain stored in a buffer store and will even be available after switching off the device another time.

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Manual PGC 9300 · EN03 · 2013-09

6 CONNECTION AND STARTUP

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

6.2

Gas connections

The incoming lines for the connections A to M (see figure 2.1) are made of 1/8" pipes with Swagelock joints.

Appropriate micro-filters are installed upstream of the analytical unit. The lines should be made of stainless steel and must be free from impurities, grease, solvents, etc.. In order to avoid any contamination with dirt or atmospheric air, the incoming lines in the relevant pressure area must be gas-tight. If it is necessary to seal off threads or joints, use only teflon tape for this purpose. You must absolutely avoid using liquid leakage detecting agents.

23

The tightness of all connections is of utmost importance for correct analyses.

The gases are to be connected to the process gas chromatograph by observing the rules for handling high-purity gases (VDI 3490 Sheet 3, Dec. 1980).

Prior to startup you must make sure that the gases used fulfill the specified requirements.

The exhaust-gas line must have a minimum inside diameter of 4 mm. A 6 mm Swagelok joint has been planned for this connection. No other devices should be connected to the line.

No overpressure is allowed to built up in the line.

6.2.1

Carrier gas connection

The connection of the carrier gas in accordance with the a.m. guidelines should first be made with the ball valve being closed. Make sure that there is a gauge pressure of 5.5 bar. After connecting is finished, the gas pipes must be sweeped by opening the clamp ring connections at the input filters.

After opening of the ball valve a waiting time of approx. 15 min is required before the power supply to the measuring element is switched on.

Then the carrier gas pressure is monitored via the internal pressure transducer and the analytical computer.

The pressure applied can be displayed at the bottom of the "Status" screen on the analytical computer, and while monitoring the value displayed it is possible to precisely adjust it.

Connected pressure values: 5.5 bar (ď‚ą 10% )

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Manual PGC 9300 ¡ EN03 ¡ 2013-09

6 CONNECTION AND STARTUP

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6.2.2

Measuring gas / calibration gas / reference gas

Connection of these gases should be made in the same way as with the carrier gas. Inlet pressure can be defined between 1.0 – 2.5 bar.

Such definition of a specific inlet pressure must be made prior to basic calibration of the device.

Once the pressure has been defined, no more changes are allowed. The pressure must be identical for all three inlets. The permissible tolerance is  10%.

24

Pressure monitoring is made in a similar way as with the carrier gas by means of an integrated pressure transducer. The assigned measured values can also be accessed at the bottom of the "Status" screen. To adjust the pressure of the measuring gas inlet, you must select the appropriate inlet in the manual mode under GC Mode (see GC 9300 Operating Manual). When the pressure adjustment for measuring gas has been performed, the setting is also suitable for calibration gas and reference gas.

6.3

Column pressure and temperature

The column temperatures and helium pressure at the injectors are determined during factory calibration of the device.

During operation these values are continuously monitored by the analytical computer. When the permissible limiting values are exceeded, a fault message is outputted and no more analysis is made. The appropriate limiting values are accessible on the analytical computer via the "Details" screen under Measuring Element/Pressure of Gas for Analysis/Max. Deviation or Measuring Element/Carrier Gas-I/Max. Deviation (manual GC 9300).

6.4

Further action

After the gas inlet pressures have been adjusted in accordance with the a.m. description, the operating mode "NORM-CAL" is to be selected in the manual mode. The chromatograph will perform one calibration run.

If the first calibration is shown as being faulty, the PGC will start a further calibration after some minutes. If also the second calibration is faulty, the PGC automatically switches to the operating mode "STOP".

After successful calibration, the PGC automatically switches to the "AUTORUN" mode.

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6 CONNECTION AND STARTUP

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6.5

Interruption of carrier gas supply

If carrier gas supply is interrupted for a short period of time, when cylinders are changed without using the switching unit, for example, the analysis has to be interrupted by selecting the mode "STOP" at the analytical computer.

If the analytical computer is set to the mode "STOP", the power supply at the measuring element must be switched off. All inlet valves at the gas distribution system (Fig. 2.1 /A,B,C,M) have to be closed.

If the carrier gas supply is ensured again (correct sweeping of pressure regulators and pipes!) the inlet pressure should be checked (inlet pressure regulation unit).

After the inlet valve for carrier gas has been opened (Fig. 2.1 / A) one more check at the analytical computer ("Status" screen) should be made. The device should remain in this status for about 15 min.

Now the power supply for the measuring element may be switched on again. After a waiting time of 5-10 minutes all inlet valves (Fig. 2.1 / B,C,M) may be opened again.

Now the analytical computer must be set to the mode "NORM-CAL". After successful calibration the mode of the analytical computer changes automatically to "AUTORUN".

If the power supply has been switched off for longer than 0.5 h, one more manual calibration should be started after 1-2 h.

If fault messages happen at the begin of operation then in most cases this may be due to residual amounts of foreign gases. Not later than after about 2 h operation time also these messages should be cleared.

25

If carrier gas supply is interrupted for a prolonged period of time, the device should be shut down.

First disconnect the measuring element from the power supply! After this the carrier gas must flow for another 15 min until the sensor in the measuring element is cooled down. Only then interrupt carrier gas supply. After pressure has dropped to approx. 0.5 bar ("Status" screen), the output of the device should be plugged. For this purpose close the outlet of the measuring element by means of a protective cap.

Then a restart has to be made in accordance with the sequence of operations described above.

Attention: Remove protective caps necessarily before, because otherwise a too high pressure is generated in the measuring element!

Attention: non-observance may lead to the destruction of the measuring element!

The biogas version (with column C) additionally includes a replaceable filter cartridge between shutoff valve and case feed-through for the helium line.

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Manual PGC 9300 路 EN03 路 2013-09

7 OPERATING MODES OF THE MEASURING ELEMENT

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

7 Operating Modes of the Measuring Element The operating modes of the measuring element can be set via the "Details" screen of the analytical computer under GC9300 Mode/Operating Mode (see GC 9300 Operating Manual).

26

7.1

Automatic analytical mode / AUTORUN

The automatic analytical mode ("AUTORUN") is the normal operating mode of the measuring element. In this mode, cyclic sampling and analysis of the measuring gas are performed. This sequence is only interrupted by the activated automatic recalibration function ("Details" screen under Calibration Parameters).

7.2

Stop mode

This mode is activated to switch off the analysis operation. After the current analysis has been completed, the operation is interrupted.

7.3

Manual calibration

In this mode it is switched over to the calibration gas inlet. One calibration cycle is performed using the specified data ("Details" screen under Calibration Parameters). After calibration has been completed, the valves are again connected to the measuring gas inlet and a continuous analysis is made. The time of the next automatic recalibration is not changed.

7.4

Reference gas analysis

The reference gas inlet is connected and a continuous analysis is made. However the number of performed analyses is limited as specified in "GC9300 Mode/REF-GAS/Max no of ref runs". Then an automatic change to "AUTORUN" occurs.

For the annual check the external calibration gas is analyzed over the reference gas inlet. This is a normal analysis and the response factors from the last automatic or manual calibration keep unchanged.

7.5

Basic calibration

One calibration cycle is performed and the determined factors are stored in the analytical computer as response factors from basic calibration (RFZ, see 4.3), together with the retention times. After the calibration cycle the analytical computer switches back to "AUTORUN".

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8 OPERATING INSTRUCTIONS FOR THE EXPLOSION-PROTECTED DESIGN

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

8 Operating Instructions for the ExplosionProtected Design 8.1

General instructions

The explosion-protected design of the PGC 9300 process gas chromatograph is an explosionprotected electrical apparatus of the “explosion-proof encapsulation” type of protection with a terminal compartment of the "increased-safety" type of protection.

Code:

27

II2 G Ex de IIB T5 or II2 G Ex de IIB T4

The device complies with the provisions of Guideline 94/9/EG (ATEX 100a).

It can be installed in areas subject to explosion hazards in zone 1 which are endangered by gases and vapours classified under danger class IIB and temperature class T4 resp. T5.

For installation and operation, the appropriate ordinances and regulations must always be observed.

With regard to explosion protection, the device has been approved for the following ambient temperature range: Ambient temperature range

Temperature class

-20°C ≤ Tamb ≤ 40°C

T5

-20°C ≤ Tamb ≤ 60°C

T4

For measuring purposes, however, the ambient temperature must be between -10 to +55°C! The device has to be protected against the weather.

8.2

Explosion-proof enclosure

The explosion-proof enclosure has no interlocking switch.

Before you open the enclosure, make sure that the voltage is switched off and then wait for one minute.

(See information on the data plate)

8.3

Increased-safety terminal compartment

For the electrical connection of the device, make sure that the correct voltage is supplied (see information on the data plate).

The cable diameters of the supply lines must be within the clamping range of the cable feedthrough. ...............................................................................................................................................................................................................

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8 OPERATING INSTRUCTIONS FOR THE EXPLOSION-PROTECTED DESIGN

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Unused openings of wire feed-throughs must be plugged by impact-resistant stoppers which cannot become loose and are secured against distortion.

When these openings are closed, make sure that the seals remain effective in order to guarantee that the degree of protection IP 54 is maintained.

28

8.4

Maintenance

Explosion-protected electrical control systems must be subjected to maintenance at regular intervals.

These intervals depend on the operating and environmental conditions. We recommend that you check the system at least once a year (possibly in conjunction with the annual official verification of the PGC).

8.5

Safety measures

In areas subject to explosion hazards, work is generally prohibited on voltage-carrying electrical apparatus (except for intrinsically safe circuits).

In special cases, it is possible to carry out work if it is guaranteed that there is no explosive atmosphere.

This can only be done if there are explosion-protected and approved measuring instruments involved.

8.6

Maintenance Work

Since explosion-proof enclosures are protected against water only to a limited extent due to the flameproof joint (IP 54), you must check for water collecting inside the enclosure.

Rusted joints must not be cleaned using abrasives or wire brushes, but should only be cleaned chemically, for example with reducing oils.

Then joints must be protected thoroughly with acid-free anticorrosive agents, e. g. ESSO RUST BAN 397, Mobil Oil Tecrex 39 or equivalent agents.

The seal of the intrinsically safe (Ex-e) enclosure must be checked for damage and replaced, if necessary.

Check cable glands and stoppers for tight fit.

Damage to the enclosures can terminate the explosion protection!

8.7

Repairs

If repairs are done to components of the device which are essential for explosion protection, such components must first be checked by an acknowledged expert before you can put them into service again.

If repairs are done by the manufacturer, they need not be approved by an expert.

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Manual PGC 9300 路 EN03 路 2013-09

9 FAULT MESSAGES

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9 Fault Messages Any fault occurring is outputted by the analytical computer as a text message with a specific number. Fault numbers are shown in the print reports.

A complete list of fault messages is included in annex E of the GC 9300 Operating Manual.

In the following, only directly analysis-related fault messages are explained.

9.1

Faults occurring during continuous analytical operation

No.

Text

Description

Cause

14 - 17

Outp. current-# limit

Current < 0/2 mA or > 21 mA

- check of limiting values in "Detail" screen under "Inputs and Outputs"

50

Gas analyzer TO

The measuring element provides no more valid data.

Communication fault The measuring element is working properly, but no measured values are received by the analytical computer.

- communication fault - fault in measuring element - cable break - incorrect TCP/IP address in the analytical computer

120

Ana: retention time

The retention time of one or more gas - faulty pressure/temperature components shows an unacceptable values (with fault 50) deviation from the basic values.

- non-permissible gas composition (Retention times in "Detail" screen under (with faults 121, 122) Calibration results, permissible - defective module deviations under "Calculation Parameters/Limit Values Ana., Cal.")

121

Ana: unnorm.

Sum

When normalization is made for 100% the - non-permissible gas composition limiting value is exceeded ("Calibration - fault of pressure/temperature results/Area sum" and "Calibration (50) - defective module parameters/Limit Values Cal.").

122

Ana: Concentration

Operating range of the modules violated

123, 82,

Ana: Hs min/max Measuring range violated Ana: CO2 min/max Ana: Ws min/max Ana: rho min/max

124, 127 130

Pres. meas. gas

131

Pres. carrier gas -I The inlet pressure of carrier gas is outside the tolerance band.

29

- non-permissible gas composition - check of limiting values in "Detail" screen under "Component Parameter"

Depending on the inlet connected, the - incorrect setting inlet pressure of measuring/calibration or - cylinder pressure - check of "Status" screen reference gas is outside the tolerance band.

- incorrect setting - cylinder pressure - check of "Status" screen

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9 FAULT MESSAGES

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9.2

Faults occurring during recalibration

The following faults are only outputted during recalibration or basic calibration. If such faults occur, calibration will be invalid. Previous response factors will be maintained. All the following measured values will be marked as faulty.

These faults cannot be acknowledged and are only reset by valid recalibration.

30

No.

Text

Description

100

Cal: retention time

The newly calculated response factors - fault of pressure/temperature (current or stream values under "Vurrent during recalibration.

Times") show an unacceptable deviation - calibration gas supply from the default values ("Calculation - faulty specified value for Parameters/Limit Values Ana., Cal.") calibration gas concentration ("Detail" screen under "Calibration Parameters") - defective module

101

Cal: response factor

The newly calculated response factors show an unacceptable deviation ("Detail" screen under "Calibration results" and "Calibration parameters/Limit Values Cal.")

103

Cal: total area

The total area for calibration deviates by - see 100 more than 30% from value for basic calibration.

9.3

Cause

- see 100

Power failure of the GC 9300

After a power failure of the analytical computer (fault 02 - power failure), first of all a self-check of the device is performed when it is restarted. After completion of this self-check, calibration is automatically initiated.

After such calibration, the analytical operation is continued.

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10 DATA STORAGE / PRINT REPORTS

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10 Data Storage / Print Reports 10.1 Data Storage 10.1.1

The general data logger

The general data logger for measured values includes the following archives with data for a period of 2 years: − Event logbook − Parameter logbook − Archive single analysis results − Archive daily mean values − Archive monthly mean values − Archive calibration results

31

The entries can be read individually on the analytical computer or downloaded with an internet browser after a network connection to a PC is established. As an internet address, the TCP/IP address of the LAN2 interface of the analytical computer has to be entered.

10.1.2

The fiscal metering data logger according to DSfG standard

The fiscal metering data logger according to DSfG standard includes the following archive groups (AG): AG 01 Hourly mean values 1 2280 entries AG 03 Measured values 1 960 entries AG 05 Hourly mean values 2 2280 entries AG 06 Corrected mean values 960 entries AG 07 Daily mean values 95 entries AG 08 Analyses 960 entries AG 09 Monthly mean values 24 entries AG 10 Hourly mean values 3 2280 entries AG 11 Calibration gas 1 200 entries AG 12 Test gas 1 700 entries AG 13 Test gas 2 700 entries AG 14 Test gas 3 700 entries AG 15 Long-term archive 70848 entries AG 17 Analog mean values 2280 entries AG 18 Calibration gas 2 200 entries AG 19 Hourly mean values 4 2280 entries AG 20 Measured values 2 960 entries AG 21 Test gas 4 700 entries AG 23 Logbook 2280 entries Reading of the entries can be made with a DSfG readout program. ...............................................................................................................................................................................................................

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10 DATA STORAGE / PRINT REPORTS

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10.2 Print Reports The analytical computer itself provides no printing functions. But it is possible to connect the analytical computer to a PC via Ethernet. With the included RMGViewGC program, it is possible to display the measured values and parameters graphically or as tables and to print them. Also displaying and printing of the chromatograms is possible.

32

A more detailed description will be available in the next version of the manual.

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11 INSPECTION AND MAINTENANCE WORK

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11 Inspection and Maintenance Work 11.1 General instructions If it is necessary to open an explosion-proof enclosure when carrying out maintenance work or repairs, it must be ensured by appropriate measures that the enclosure is not exposed to an explosive atmosphere.

If it is necessary to provide access to the electrical units of the analytical computer or the measuring element, the following precautions must be observed:

33

- The entire device must be disconnected from the power supply.

- When work is carried out on electronic units, a connection must be established between an earthed object and the body of the person concerned.

See Chapter 6.5 for interruption of the carrier gas supply.

11.2 Regular maintenance work 11.2.1

Draining condensate at the measuring element

Membrane filters with condensate collecting tanks are located on the measuring element (Figure 2.1, item 7, one per gas stream, standard for biogas, option for natural gas). From time to time, the condensate has to be drained by opening the emptying valves below the tanks. The interval is determined by the moisture of the sample gas. The optimum interval can be determined by starting with draining the condensate at short intervals (such as weekly). In case of small amounts of condensate flowing out, the interval should be prolonged step by step until the amount of condensate is about half of the volume of the tank.

11.2.2

Exchanging carrier gas cylinder

For the operation of the PGC 9300, an inlet pressure of 5.5 bar is required for the carrier gas. This value may be underrun by up to 10%, below this limit an alarm is triggered. As the carrier gas also has a protective function and prevents oxygen from getting into the measuring element, this should never happen! If this nevertheless happens, the measuring element automatically switches off within the range of 2 to 3 bar.

Attention: If an automatic shut-down occurs, it cannot be ruled out that in the meantime air has penetrated into the measuring element. In this case the power supply must be switched off before exchanging the cylinder, since the measuring element switches on again with sufficient pressure. After the cylinder has been exchanged, the measuring element must be sweeped for at least 15 minutes. If an alarm message occurs after re-commissioning, an on-site service is required.

Therefore a cylinder exchange should be done already when a message from the contact pressure gauge of the empty cylinder is sent. ...............................................................................................................................................................................................................

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11 INSPECTION AND MAINTENANCE WORK

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To switch from the empty cylinder to the full one, a changeover unit is mounted above the carrier gas cylinders. There are two variants available:

34

Manual changeover unit The changeover must be made manually: first close the valve of the empty cylinder (5a) and then immediately open the valve of the full cylinder. To ensure that the changeover takes place early enough, the contact pressure gauge (3) must be adjusted appropriately. For this purpose turn the cover of the contact pressure gauge counterclockwise, take it off and move the red marker.

Automatic changeover unit Here the changeover takes place automatically, driven by the pressure of the full cylinder. To ensure the function of automatic changeover, the pressure in the full cylinder must be at least 150 bar. Here, it is recommended to leave the default setting at the contact pressure gauges unchanged.

Exchanging cylinder During the exchange of a cylinder, it must be prevented that air gets into the system! Therefore, it is absolutely necessary that the cylinder exchange (with manual changeover unit as well as with automatic changeover unit) is performed according to the following instructions: 1. Close the left or right shut-off valve (5a), depending on the cylinder which has to be exchanged.

2. Disconnect the cylinder at the connecting point from the high-pressure helix and exchange it.

Then open the valve of the new cylinder.

3. Loosen the cap on the corresponding shut-off valve (5b).

4. Open the associated shut-off valve (5b) for at least 5 seconds to purge the line system with carrier gas.

5. After purging, close the corresponding shut-off valve (5b) again and tighten the cap again.

6. With the automatic changeover unit, open the associated shut-off valve (5a) again. The cylinder is now ready for the next changeover.

With the manual changeover unit, keep the shut-off valve (5a) closed if the cylinder has not to go into operation immediately.

In the biogas version, the gas supply unit may have four positions for carrier gas cylinders. In this case there are always two cylinders in parallel. This means that both cylinders must always be simultaneously open or closed and in case of a cylinder exchange also both cylinders must be exchanged simultaneously. The high-pressure helixes then have to be purged separately one after the other! First purge the connecting line of the outer cylinder (far left or right) and then close the valve at the high pressure helix. Then purge the second high-pressure helix and finally open the valve again.

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Manual Changeover unit Type USE-3M For 2 carrier gas cylinders (helium 5.0)

640 610

210 240

3

0-250bar

0-250bar

D 5b

38

3 5a

240

5a

280

1

5b 2

35

Ø8.5

7

8

A 6 1.) Two-stage pressure regulator with safety relief valve 2.) Outlet pressure gauge 0-10 bar 3.) Inlet pressure gauge as a contact pressure gauge (with reed limit signal) 4.) Restrictor ø 0.4 mm 5.) Shut-off valves 6.) High-pressure helix with cylinder connection acc. to DIN 477 No. 6 for helium 7.) Ex(i) terminal box for contact pressure gauges 8.) Test port with shut-off valve (option)

4 C B 6 A.) Connection for carrier gas cylinder 1 (inlet pressure max. 200 bar) B.) Connection for carrier gas cylinder 2 (inlet pressure max. 200 bar) C.) Outlet carrier gas with 5.5 bar to PGC 9300 D.) Exhaust line from safety relief valve (opening pressure 6 bar) E.) Outlet for purging Supply line to connection C: 1/8” pipe with Swagelok screw fitting.

Supply line to connection D: 12 mm pipe with Swagelok screw fitting.

Total weight: 12 kg

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11 INSPECTION AND MAINTENANCE WORK

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Automatic Changeover Unit Type USE-3A For 2 carrier gas cylinders (helium 5.0)

640

36

610

220 38

240

D1

3

5a 5b

4

D2

0-250bar

240

280

0-250bar

5b 5a

3

0-16bar

C 7

8

4 A

Ø8.5

1 9

6 1.) Changeover station with primary pressure regulator and safety relief valve 2.) Secondary pressure regulator with safety relief valve 3.) Input pressure gauge as a contact pressure gauge 0-250 bar (with reed limit signal) 4.) Output pressure gauge 0-16 bar 5.) Shut-off valves 6.) High-pressure helix with cylinder connection acc. to DIN 477 No. 6 for helium 7.) Ex(i) terminal box for contact pressure gauges 8.) Restrictor ø 0.4 mm 9.) Test port with shut-off valve (option)

2 B 6 A.) Connection for carrier gas cylinder 1 (inlet pressure max. 200 bar) B.) Connection for carrier gas cylinder 2 (inlet pressure max. 200 bar) C.) Outlet carrier gas with 5.5 bar to PGC 9300 D1.) Exhaust line from safety relief valve at primary pressure regulator (opening pressure 13 bar) D2.) Exhaust line from safety relief valve at secondary pressure regulator (opening pressure 6 bar) E.) Outlet for purging Supply line to connection C: 1/8” pipe with Swagelok screw fitting.

Supply lines to connections D1+D2: 12 mm pipe with Swagelok screw fitting.

Total weight: 12 kg

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11.2.3

Exchanging the carrier gas filter

The molecular sieve column (module C) is very sensitive to moisture. So an additional filter is installed on all measuring elements with measurement of oxygen/hydrogen at the carrier gas input (Figure 2.1, item 6). It is a moisture filter (1) or a combined filter (2) that filters out water and oxygen from the carrier gas. Both versions can be ordered as a spare part from RMG, the type designation is: (1) Gas Clean Moisture Filter (Agilent co.)

(2) Gas Clean Filter GC MS (Agilent co.)

It can be seen on a colour display, whether a filter has to be exchanged. There are colour fields printed on the filter cap with the appropriate colours for mint condition (ORIGINAL) and saturated (SATURATED), each for moisture and oxygen (if available). As soon as one of the two display fields takes the colour of SATURATED, the filter must be exchanged.

37

The filter exchange is carried out as follows: 1. Set the operating mode to STOP at the analytical computer and wait until the current analysis or calibration is finished 2. Switch off the power supply oft the measuring element 3. Disconnect the carrier gas supply at the gas supply unit 4. Loosen the knurled screw fitting and unscrew the filter. Hold the filter with the other hand because there may be a residual pressure in the filter.

5. Slide the knurled screw fitting over the new filter 6. Remove the metal cap on the new filter 7. Insert the new filter and turn it until it locks into place (wrong mounting thus not possible) 8. Tighten knurled screw fitting again 9. Restore carrier gas supply 10. Check the surroundings of the knurled screw fitting with a gas detecting device for leaks 11. Wait at least 15 minutes until filter and measuring element are purged. (Attention: insufficient purging time may cause the destruction of the measuring element!)

12. Switch on the power supply of the measuring element again 13. Set the operating mode back to AUTORUN at the analytical computer 14. Enter filter exchange in the maintenance manual.

Filter cap with colour codes

Filter granulate

Colour display for humidity (and oxygen)

Knurled screw fitting

The saturated filter is considered as hazardous waste and must be disposed of in accordance with the local laws. ...............................................................................................................................................................................................................

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13 Technical Data of the Measuring element

38

Power supply:

21V DC - 27V DC

Power input:

110 W

Starting current:

10 A in the first 3 minutes

Ambient temperature range: Air humidity:

-10°C - 55°C 0% - 95% R.H. Moisture condensation is not permitted.

Safety classification:

II2 G Ex de IIB T5 (up to 40°C) II2 G Ex de IIB T4 (up to 60°C)

Dimensions:

See figure 2.1

Weight:

75 kg

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Sampling Probe Type PES 50S

1

Connection pipe

8 5

Ø4mm or Ø6mm

39

Red mark

2 Pipe fitting with connecting thread according to DIN/ISO 228-1 for screw hole DIN 3852-2 form X or Y. Sealing with gasket according to DIN7603 thread size G1/2"

pipe wall thickness

Baseplate

4 7

6

Weldolet G1/2”, G3/4” or G1” with screw hole DIN 3852-2 form X or Y. Provided by the customer.

3

min. Ø20mm

The chamfer of the pipe must stand against the direction of the flow.

Adjustment of the pipe at assembling in conformity with the position of the mark.

design parameters DN Ø nominal diameter weldolet thread

inch

weldolet height L2

mm

pipe wall thickness

mm

engaged length L3 (Pos.3)

mm

connecting pipe Ø

mm

cover

yes

no

isolated screw connection

yes

no

Sectional view C-C

9 10

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11 INSPECTION AND MAINTENANCE WORK

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Sampling Probe Type PPS 02-R extendable under pressure

Sample outlet pipe,dia.6mm

40

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Isolated screw connection for electrical isolation Stopcock Stopcock with back-up ring for extending/ retracting tool Staight-way screw connection Sample inlet/ feedback Flanged-end connection head Probe tube, dia. 12mm Locking device (M10 nut) Cover (Option) Ball valve (to be provided by customer) Weldolet (to be provided by customer)

Operating pressure 100 bar max.

The connection head can be designed as follows: DIN flange DN40/50 pressure class PN10-100 ANSI flange 1.5“/ 2” pressure class ANSI 150-600 The engaged length L1 can be adjusted between 330 to 430mm, 430 to 530mm or 585 to 685mm during initial installation.

The probe length L2 is between 300mm and 400mm depending on the engaged length L1.

Recommended engaged length L3=1/3 DN (50mm min.)

DN

L3

min.dia.25mm dia.12mm

All probe components are made of high-quality steel.

O-rings are made of Viton.

Screw connections and stopcocks are desingned for Swaglok couplings.

Weldolet, ball valve, seals, screw bolt and nut between the probe and the ball valve are not included in the delivery.

Gas pipe

Make sure that the hole in the piping is centrically adjusted with the pipe section and the ball valve and has a minimum diameter of 25mm.

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Manual PGC 9300 · EN03 · 2013-09

11 INSPECTION AND MAINTENANCE WORK

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Pressure Reducing Unit Type DRS 200 (wall installation) 660 mm 612 mm

41

630 mm

aeration

fixing hole 11

ventilation

520 mm 1.) isolation cabinet with window 2.) pressure reducer inlet pressure max. 100 bar outlet pressure 0.14-7 bar 3.) primary pressure gauge 4.) secondary pressure gauge 0-6 bar 5.) relief valve with 3 bar opening pressure 7.) filter 8.) test port (low pressure) 9.) shut-off valve 10.) Ex heating 100 W with 30°C fixed value thermostat in connecting cable, keeps cabinet frost-free until -25°C 11.) Ex(e)(i) connection box for pos. 10 and sample gas pipe heating 12.) holder for wall installation 13.) restrictor ø 0.4 mm

250 mm Options: 6.) coalescence filter 14.) test port (primary pressure) 4.) with limiting value contact (adjustable) A. measuring gas inlet B. measuring gas outlet C. vent line of relief valve (12 mm pipe) D. vent line of pressure reducer (12 mm pipe) E. outlet for condensate (12 mm pipe) pipes for connections A,B: 1/8”, 4 mm, 6 mm.

Shut-off valves and fittings in Swagelok system (stainless steel) Total weight approx. 30 kg

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Manual PGC 9300 · EN03 · 2013-09

11 INSPECTION AND MAINTENANCE WORK

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Pressure Reducing Unit Type DRS 200 (installation on rack)

C

D

C,D

320 mm

42 690mm shelter

ventilation 516 mm A E B

A

A

min. 2000 mm

aeration

250 mm

section: A-A 500 mm 460 mm

460 mm 500 mm

cable-clampassembly Ø 60.3 mm ( Ø 2“ )

grounding screw fixing hole 11 mm

1.) rack (stainless steel) 2.) isolation cabinet with window 3.) pressure reducer inlet pressure max. 100 bar outlet pressure 0.14-7 bar 4.) primary pressure gauge 5.) secondary pressure gauge 0-6 bar 6.) relief valve with 3 bar opening pressure 8.) filter 9.) test port (low pressure) 10.) shut-off valve 11.) Ex heating 100 W with 30°C fixed value thermostat in connecting ckable, keeps cabinet frost-free until -25°C 12.) Ex(e)(i) connection box for pos. 11 and sample gas pipe heating 13.) restrictor ø 0.4 mm 15.) insect safety-sieve

Options: 7.) coalescence filter 14.) test port (primary pressure) 5.) with limiting value contact (adjustable) A. measuring gas inlet B. measuring gas outlet C. vent line of relief valve (12 mm pipe) D. vent line of pressure reducer (12 mm pipe) E. outlet for condensate (12 mm pipe) pipes for connections A, B: 1/8”, 4 mm, 6 mm.

Shut-off valves and fittings in Swagelok system (stainless steel) Total weight approx. 70 kg

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Manual PGC 9300 · EN03 · 2013-09

11 INSPECTION AND MAINTENANCE WORK

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Pressure Reducing Unit Type DRS 200 Functional Diagram

43

to atmosphere

1

outlet pressure = 0.14-7 bar

8

7

1

1

1

5

1

4

8 5

inlet pressure = 100 bar (max)

6

10

9 3

2 1

1

1

1.) shut-off valve 2.) coalescence filter 3.) filter 4.) pressure reducer 5.) relief valve 6.) primary pressure gauge 7.) secondary pressure gauge 8.) test port 9.) restrictor 10.) flow alarm, relief valve (option)

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Manual PGC 9300 路 EN03 路 2013-09

11 INSPECTION AND MAINTENANCE WORK

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Pressure Reducing Unit Type DRS100

8

7

6

5

4

3

2

1

186

159

44

A

C

B 9 350 375

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Manual PGC 9300 路 EN03 路 2013-09

11 INSPECTION AND MAINTENANCE WORK

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Pressure Reducing Unit Type DRS100 Functional Diagram

45

6 outlet pressure = 0-8 bar

5 4

7

2

inlet pressure = 100 bar

3

1

1.) shut-off valve (needle) 2.) gas filter 3.) restrictor 4.) pressure reducer 100/8 bar 5.) relief valve (8 bar) 6.) pressure gauge 0-16 bar 7.) gas dryer

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Manual PGC 9300 路 EN03 路 2013-09

11 INSPECTION AND MAINTENANCE WORK

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Gas Supply Unit with changeover unit for two carrier gas cylinders 10l

Connections: A) carrier gas outlet B) int. calibration gas outlet C) ext. test gas outlet D1) vent line of relief valve (carrier gas) D2) vent line of relief valve (carrier gas) for fine pressure regulation, only with autom. changeover unit D3) vent line (int. calibration gas) D4) vent line (ext. test gas)

660

A B C ext. test gas 10l

int. calibration gas 10l

carrier gas 10l

carrier gas 10l

1450

1630

46

holes for fixing on the floor fixing hole Ø 11 mm

370 340

15

1300

1.)

2.)

3.)

4.)

5.)

6.)

7.)

8.)

changeover unit autom. or manually for two carrier gas cylinders 10l int. calibration gas cylinder (heated) with pressure regulator and relief valve ext. test gas cylinder (heated) with pressure regulator and relief valve thermostat for cylinder temperature Ex(e) connection box for Ex cylinder heating Ex(i) connection box for contact gauges (carrier gas cylinders) Ex(i) connection box for room and cylinder thermostat high pressure helix (stainless steel) with cylinder connection acc. to DIN 477, No. 6 or BS 341, No. 3 9.) high pressure helix (stainless steel) with cylinder connection acc. to DIN 477, No. 14 or BS 341, No. 4

option: 10.) room thermostat 11.) Ex solenoid valve for gas shut-off int. calibration gas, test gas weight without cylinders approx. 94 kg 1/8“ pipe to the connections A, B, C Ø 12 mm pipe for the connections D1-D4 all pipes and pipe fittings in Swagelok system from stainless steel

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Manual PGC 9300 · EN03 · 2013-09

11 INSPECTION AND MAINTENANCE WORK

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Gas Supply Unit with changeover unit for four carrier gas cylinders 10l

47

660

ext. test gas 10 ltr.

int. calibration gas 10 ltr.

carrier gas 10 ltr.

carrier gas 10 ltr.

carrier gas 10 ltr.

carrier gas 10 ltr.

1450

Connections: A) carrier gas outlet B) int. calibration gas outlet C) ext. test gas outlet D1) vent line of relief valve (carrier gas) D2) vent line of relief valve (carrier gas) for fine pressure regulation, only with autom. changeover unit D3) vent line (int. calibration gas) D4) vent line (ext. test gas)

1235

holes for fixing on the floor fixing hole Ø 11 mm

370 340

15

1300

1.)

2.)

3.)

4.)

5.)

6.)

7.)

8.)

changeover unit autom. or manually for four carrier gas cylinders 10l int. calibration gas cylinder (heated) with pressure regulator and relief valve ext. test gas cylinder (heated) with pressure regulator and relief valve thermostat for cylinder temperature Ex(e) connection box for Ex cylinder heating Ex(i) connection box for contact gauges (carrier gas cylinders) Ex(i) connection box for room and cylinder thermostat high pressure helix (stainless steel) with cylinder connection acc. to DIN 477, No. 6 or BS 341, No. 3 9.) high pressure helix (stainless steel) with cylinder connection acc. to DIN 477, No. 14 or BS 341, No. 4

option: 10.) room thermostat 11.) Ex solenoid valve for gas shut-off int. calibration gas, test gas weight without cylinders approx. 94 kg 1/8“ pipe to the connections A, B, C Ø 12 mm pipe for the connections D1-D4 all pipes and pipe fittings in Swagelok system from stainless steel

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Manual PGC 9300 · EN03 · 2013-09