Process Gas Chromatograph Transmitter

Transcription

1 GCX Product Data Sheet PDS A01 May, 1999 Process Gas Chromatograph Transmitter The first multi-application, multiconfiguration process gas chromatograph in a field mount transmitter package Supports thermal conductivity (TCD) or flame ionization (FID) detectors and analysis of gaseous or liquid phase samples. Approved for use in Class I, Zone 1 Gr. IIB+H2 environments Modular electronics and EZSlide Oven TM assembly minimize maintenance and mean-time-to-repair (MTTR) Compact size and slim horizontal profile dramatically reduces installation space requirements Operates in stand-alone mode or as a part of a process GC network Advanced electronic pressure control reduces maintenance requirements and cycle times Integral Quick-View LED display panel provides instant status information on instrument operation Intuitive and sophisticated Microsoft Windows * based man-machine-interface (MMI) program simplifies chromatograph commissioning, operation, and troubleshooting Field-mountable enclosure minimizes the need for an environmentally controlled shelter or continuous air feed DESCRIPTION The GCX is the world s first process gas chromatograph configured as a field mount transmitter which has been specifically designed for advanced multi-component, multistream chromatographic analysis over a wide range of industrial applications. Unlike conventional GC transmitters which are suitable for only niche applications, the GCX introduces the benefits of smaller size, reduced utility requirements, field mounting, and completely modular construction for a broad range of process applications. Enclosure The instrument is housed in an explosion proof, dual compartment enclosure suitable for hazardous area installation. A volume-limiting barrier effectively provides separation between the electronics section of the instrument and the chromatographic analysis section. The GCX enclosure has been engineered to allow field mounting without additional ambient controls or shelters in all but the harshest environmental conditions. In most of these installations a three-sided shelter providing minimal protection from direct sun, rain, or snow is generally adequate. In rare instances where additional protection is required the GCX packaging is still a valuable asset since shelters can be smaller in size and need be designed only to prevent ambient temperature extremes. Visit our website at On-line ordering now available.

2 Increased Safety Junction Box Electronic Assembly O-Ring Cover, Electronics Compartment Oven Plate Assembly Cover, Oven Compartment PCB/Manifold Assembly Oven Assembly O-Ring Figure 1. GCX Modular Construction Field Wiring Screw type terminal blocks housed in an increased-safetybox (ISB) mounted above the GCX electronics enclosure provide the interface for termination of power and communications conductors. When the GCX is installed in a hazardous area, power and signal wiring may be terminated at the ISB via armored cable (European convention) or, by increasing knockout size, rigid conduit (U.S. standard). Power and Communications The GCX includes a universal power supply (90 to 264 VAC) or may be optionally powered by a direct 24 VDC supply. Signal interconnection consists of the primary RS485 multi-drop network that will support from 1 to 36 instruments. Also included is an RS 232 interface for local MMI support, a local chromatogram output, 6 digital inputs and 6 digital outputs for various control, indication, and alarm functions, and an RS422 Modbus interface for interconnection with a host computer or DCS. The instrument also features an integral operator interface/ display panel. LED status lights indicate the operational status of the instrument including: cycle status, stream being sampled, detector status, oven status, VLSIV or SHS temperature zone status, valve status, and normal-warningfailure common alarm status. Sample System Configurations For single stream applications the GCX is designed for installation without the need for additional sample handling equipment. A clean, dry, particulate free, pressure regulated sample is all that is required. Provision for introduction of calibration standards, carrier gases, and/or FID fuel and air support gases are provided through conventional Swagelok type fittings. Where additional sample stream capability is required the instrument may be provided with an integral explosion proof sample handling system module capable of supporting heated samples and up to four streams. If instrument air is available or should even greater stream capability be required, the instrument may be fitted with a binary encoder for stream selection allowing use of pneumatically driven sample system valves for up to 15 process streams plus calibration. Page 2

3 FEATURES The GCX provides the advanced chromatographic and analytical features of a world class instrument. Innovative new features allow the transmitter configuration and the gas chromatographic methodology to be married for the first time. Integral Controller At the heart of the GC transmitter is a powerful microprocessor based system controller that provides analysis of up to 20 components and/or pseudocomponents for each stream. This analysis may be supported by up to 2 calibration methods and automatic stream sequence programming of up to 36 steps. Automatic peak detection, base-line correction, and slope detect sensitivity levels may also be individually set for each component and method. Automatic storage of the last measured chromatogram for each stream and calibration is automatically provided. The GC controller also provides non-volitile storage for all system operating parameters and operator selectable functions so, that should power be interrupted, no data is lost. Automatic calibration options include; Auto-calibration with operator verification prior to accept, auto-calibration with auto update, or auto-calibration over an operator specified number of cycles with averaged results auto updated. Configuration Options A variety of hardware options dramatically increase the number and types of applications that may be served by the GCX. Available instrument options include; single or dual carrier thermal conductivity (TCD) detectors, flame ionization (FID) detector, single or dual conical rotary or piston plunger type 10 port valves, vaporizing liquid sample inject valve (VLSIV), and an optional FID detector with methanator. Modular Construction The modular construction of the GCX offers maximum uptime and minimum MTTR (mean-time-to-repair) by simplifying service to routine pull and replacement. In the electronics section the GCX printed circuit board assemblies are euro-card slide rail mounted and may be removed and/or replaced without the use of tools. Sophisticated diagnostics allow, in most cases, service personnel to identify the problem component before arriving on site, ensuring that most electronics problems require only a single visit. The modular component concept has been further implemented in the unique design of the GCX oven. In this assembly all chromatographic components including: columns, detector, valves, actuators, heaters, temperature sensors, and electronic pressure/flow control components can be removed and replaced as a single unit. The chromatograph oven as a replacement part is central to the GCX transmitter concept and maintenance philosophy. Complete replacement of the oven assembly as opposed to field repair of individual oven assembly as opposed to field repair of individual oven components provides many advantages. First, repair personnel need not wait for an oven cool-down period to begin repairs. The oven can be removed as soon as the instrument has been Modular Oven Assembly can be replaced as a unit. powered down. In fact, oven removal, replacement oven re-installation, and instrument re-start can be completed in about 60 minutes. Secondly, all replacement ovens are pre-calibrated for your specific application. Calibration and instrument re-start can be completed on the first attempt without operator intervention or adjustment, maximizing instrument availability. Also, repairs to the primary oven assembly can be completed at your pace in your facility or ours. No more worries about having the correct valve seat, column, heater, or fuse in stock. The correct replacement parts are always available because a spare oven is a spare chromatograph. Electronic Pressure Control The GCX augments the traditional chromatographic components used in the oven/analysis section of the device with state-of-the-art, patented, fluidic transistors or fluistors. These assemblies are actually miniaturized pressure/flow controllers that provide a number of advantages over conventional pressure regulators. Fluistors not only offer a low cost alternative, they allow precise control of critical parameters in approximately twenty percent of the space required by conventional methods. Electronic pressure control is also used in the GCX to minimize routine maintenance by eliminating routine adjustments. Typically, changes in GC base-line response are due to changes in critical flow paths or column performance and must be compensated for with needle valve adjustments. With the GCX, micro-pressure controllers eliminate these routine adjustments. The needle valves used to establish baseline response need only be adjusted if, and when, column replacement is required. Unlike instruments that utilize micro-valves or other less-than-robust components for potentially corrosive, particulate laden sample gases, the GCX fluistor assemblies control only ultra- pure carrier and/ or detector support gases. Dependent upon application and instrument configuration the fluistor assemblies can also be used to modulate the column head pressure reducing elution time and improving overall analysis cycle time. Page 3

4 GCX Man Machine Interface (MMI) Software Designed to operate in the Microsoft Windows* environment on a Pentium or higher personal computer, the GCX MMI software is a highly sophisticated, remarkably intuitive program. All configuration data is provided both pre-programmed into your instrument s non-volitile memory, and supplied on magnetic media as a backup or for upload into the MMI. Installation of the MMI software is fully automatic with an installation wizard that walks the operator through each step. Once installed the MMI software is instantly ready to provide a direct monitoring and control interface to a single GCX Gas Chromatograph Transmitter or an entire network of instruments. The MMI software provides a graphic indication of all instruments on the network. Operators may modify tag names and communications parameters or access a specific instrument for input or modification of operating conditions. Additionally all data input screens provide scroll bar access to every GCX on the network. Exiting the setup or display function screens is not required to change the instrument to be modified. All setup functions are selectable from one convenient tabular setup menu screen. Component names, gate times, peak detection methods, base line correction mode, and more are accessible from the component setup screen. Additional setup functions include cycle timing functions, automatic calibration frequency and type, calculations to be performed and pseudo-component setup, analog output calibration, and Modbus setup are all provided in similar fashion. Each setup function screen allows both reading from the selected GCX, writing to the Controller, and the ability to save an unlimited number of instrument configurations in MMI data files for rapid re-configuration or re-commissioning of any instrument. Data view screens provide operators access to time and date stamped logs of the selected instrument s operation. All GCX MMI data can be saved in Microsoft Access compatible files should additional averaging, sorting, graphing or charting of data be desired. In their native format, the data log provides an indexed listing of the GCX network address, tag number identifying the data source, the date of the analysis, the time of the analysis, the stream sampled, and the calculated concentrations for each measured component. For safety, the operator is asked to select a default file size of 250 kb, 1mb, 2 mb, or 10 mb prior to enabling data logging functions. This prevents accidental overfill of hard drive storage space and potential system crashes. Page 4

5 The calibration data view screen allow the operator to simultaneously view both the calculated concentration data from the current and previous calibration cycle, and the chromatogram for the most recent calibration. The percent change, calibration standard value, and the method used are also displayed. The operator may, if in review calibration mode, select individual component values for calibration update or select to accept all. This screen may also be used to review stored calibration data that has been saved to disk. The chromatogram view screen allows the operator to select the data plot parameters including; X and Y axis scaling, data and plot colors, gate time display, and many other options. Chromatograms are displayed in real time as elution is occurring, not batch updated at the end of the cycle. Also displayed is the detector being monitored, method in use, stream being analyzed, and a cycle count timer. Systems configured for dual carrier applications have the option of displaying a split-screen chromatogram view that monitors the outputs of both detectors 1 and 2. The chromatogram view may be used to monitor real time data or to review chromatograms that have been saved to disk. The MMI includes several comprehensive diagnostic data views that display specific operational parameters useful in diagnosing problems, should they arise. Diagnostic data displays include indication of power supply voltages, detector filament currents (TCD) air/fuel flows (FID), detector signal output, oven detector sample handling system or vaporizing liquid inject valve, and heated sample line heater currents and temperatures. Diagnostic views also include status and cycle mode indication. The GCX man-machine-interface software is both sophisticated and comprehensive while providing a straight forward, intuitive feel with which even chromatography novices will be comfortable. Page 5

6 APPLICATIONS Unlike other GC transmitter products the GCX is at home in the refinery or on the pipeline. This instrument, with its wide variety of configurations, available detectors, and optional components, has the greatest applications versatility of any transmitter product available today. Now for the first time process facilities of all types can benefit from the reduced installation cost, reduced operating cost, and increased availability once reserved for a very few applications. Examples of typical GCX applications include: REFINING ilight Hydrocarbons and Olefins in Cracked Gas ilight Hydrocarbons in Separator Overheads and Bottoms ivoc s in Refinery Exhaust imtbe Purity ichlorinated Hydrocarbons/Aromatics in Water SPECIFICATIONS General/Analysis Components: Up to 20 Maximum per stream Calibration: Full Automatic or Manual Reference to Calibration Stds. Internal Normalization Relative Response Factors Calibration Methods: Two Detection Functions: Peak Height or Integrated Area Auto Peak Detect Variable Peak Detect Sensitivity Baseline to Baseline Baseline to Perpendicular Perpendicular to Baseline Forced Integration Calculation Packages: Standard - Add - Subtract - Divide - Multiply - Pseudo - component calculation capability Optional - BTU, ISO and GPA Standards Streams: with Integral Zone 1, Group B, EExd Assembly Four Streams Maximum (3 + 1 Cal or Cal) with external pneumatic SHS Assembly up to Sixteen Maximum ( Cal or Cal) À All static performance characteristics are with operating variables constant. Specifications subject to change without notice. AIR SEPARATIONS AND SEMICONDUCTOR itrace Contaminants in production or supply iquality Assurance in Traceable Standards imethane/non-methane Hydrocarbon Analysis PIPELINE AND GAS PRODUCTION ibtu, Heat Content Analysis icompliance with ISO 6976 or GPA Standards icustody Transfer (When supplied with the FloBoss 407 Flow Manager from Fisher Controls, the GCX offers a complete analysis solution to AGA 3 or AGA 8 requirements) CHEMICALS itoluene, Ethyl-Benzene, and Meta-Xylene in Para Diethylbenzene iimpurities in Vinyl-Chloride Monomer Production iethyl-benzene in Styrene iethylene in Demethanizer Overhead PHARMACEUTICALS AND FOOD iethylene Oxide in Sterilization Applications imethylene Chloride in Tablet Drying Power: 180 Watts Maximum at Start Up 120 to 140 Watts Nominal Over Voltage Category II Optional 24 VDC Power Cable Requirements: AC Operation (100 to 240 VDC); 16 AWG, Minimum DC Operation (24 VDC); 12 AWG, Minimum Oven Temperature: 140 to F (60 to140 0 C) isothermal control to 0.1 C Detectors: TCD Detector Accuracy: Reproduceability: FID Detector Accuracy: Sensitivity: Reproduceability: Sample Gas: Carrier Gas: Single or Dual Carrier Thermal Conductivity Detector (TCD), (minimum detectable limit) or Flame Ionization Detector (FID) Application Dependant Typ. < +/- 1% Full Scale Typ BTU/1000 or 0.5% Full Scale Application Dependant Typ. < +/- 1% Full Scale 0 to 4 ppm CH4 equivalent to 10,000 ppm std. Typ.< +/- 0.5% Full Scale Supply Pressure; 5-25 PSIG Particulates; < 7 microns, 0.1 um recommended Supply Pressure; 10 to 30 PSIG Utilization: 40 cc/min Maximum Nominal; 15 to 20 cc/min (application dependent) Dew Point; -62 C to -68 C (-80 F to -90 F) Purity; % or Better Page 6

7 Reproduceability: Typ BTU/1000 or 0.5% Full Scale Fuel Gas (FID Detector Only): Supply Pressure; 10 to 30 PSIG Utilization; 40 cc/min. Maximum Nominal; 15 to 25 cc/min. (application dependent) Ultra Pure Grade Hydrogen (H2) Recommended Purity; % Dew Point; -68 C (-90 F) Total Hydrocarbons; <1 ppm (CH4 equivalent) Burner Air (FID Detector Only): Supply Pressure; 10 to 30 PSIG Utilization; 40 cc/min. Maximum Nominal; 10 to 25 cc/min. (application dependent) Breathing Grade Air Recommended Dew Point; - 68 C (-90 F) Vaporizing Liquid Sample Inject Valve (VLSIV): Operating Temperature: 60 to 225 C (140 to 437 F) Operating Pressure: 250 PSIG Maximum Injection Volume: 0.5 to 10 ul Methanator: Operating Temperature: 485 to 550 C (905 to 1022 F) Operating Pressure: 5 to 20 PSIG Conversion Efficiency: 100 cc/min Max Flow Mounting: 4 or 6 Pipe, Rack, or Wall Mount Weight: Base Assembly 64 Lbs (32.2 Kg) with Integral SHS 115 Lbs (52 Kg) Environmental Area Classification: North America Class 1, Exd, e IIB (+H2), T4 Europe Category 2, Zone 1, EEx de IIB (+H2), T4 Compliances: USA - NRTL - FM (pending) Canada - CSA EU - CE - ATEX - NAMUR-EMC Australia /New Zealand - C-Tick (EMC) Housing: Single cast aluminum explosion-proof and weather housing with or without integral sample handling module, and increased safety junction box. Field mountable; rating NEMA 3R, IP54 Ambient Temperatures: Á 15 to F (-10 to 50 0 C) Relative Humidity: 5 to 100% Communications Inputs/Outputs: Digital: RS 485 Multi-Drop Network Maximum Distance; 1219 Meters (4000 Ft.) (Supports up to 36 GCX) RS 232 Serial Data Maximum Distance; Meters (40.0 Ft.) RS 422 Modbus (Half Duplex, Modicon type 584, Remote Terminal Unit Protocol) Maximum Distance; 1219 Meters (4000 Ft.) Analog: Current Outputs: Up to Six Isolated 4-20 ma outputs into 250 ohms Max load Digital Outputs: Six Form B Contacts, Max Current 100 ma 24 VDC Digital Inputs: Six 5 to 24 VDC Signals (10 ma) Chromatogram: Chromatogram locally available at GCX Increased Safety Box + 5 to 5 10 ma max Á Ultimate lower temperature limit determined by sample system configuration. Page 7

8 OUTLINE DIMENSIONS FOR GCX PROCESS GAS CHROMATOGRAPH TRANS- MITTER Figure 2-1 GCX with Integral Sample Handling System Figure 2-2 Single Stream plus Calibration or for use with external sample system PIPE MOUNTING DETAIL Detail 6 Pipe Mount Detail 6 Pipe Mount Detail 4 Pipe Mount Detail 4 Pipe Mount Page 8

9 Figure 2-3 Typical GCX-FID Piping and Interconnect Page 9

10 Figure 2-4 GCX with Vaporizing Liquid Sample Valve Option Page 10

11 GCX PROCESS GAS CHROMATOGRAPH TRANSMITTER ORDERING INFORMATION G GCX PROCESS GAS CHROMATOGRAPH TRANSMITTER A B Power Supply Selection VAC Universal Special T D F M Detector Selection Thermal Conductivity Dual Carrier Thermal Conductivity Flame Ionization Methanator with FID Oven Hardware Configurations and Application Type 1 BTU ( C3+ or C4+) 2 BTU (C6 +) A Vapor- Single Column / Stripper B Vapor- Single Column / Back Flush C Vapor- Dual Column / Stripper D Vapor- Single Column / Stripper + Single Column / Stripper E Vapor- Single Column / Stripper + Single Column / Back Flush F Vapor- Dual Column / Back Flush G Vapor- Single Column / Hart Cut / Stripper H Vapor- Single Column / Stripper / Detector By-pass I Vapor- Single Column / Back Flush / Detector By-pass J Liquid- Single Column / Stripper K Liquid- Single Column / Back Flush L Liquid- Dual Column / Stripper M Liquid- Dual Column / Back Flush N Liquid- Single Column / Hart Cut / Stripper O Liquid- Single Column / Stripper / Detector By-pass P Liquid- Single Column / Back Flush / Detector By-pass Q Liquid- Single Column / Stripper / Swab Out R Liquid- Single Column / Back Flush / Swab Out S Special XXX Applications Selection Rosemount Application Engineering Standard Application Special Z A B C Standard I/O Selection None Two 4-20 ma Analog Outputs, 6 Digital I/O s Four 4-20 ma Analog Outputs, 6 Digital I/O s Six 4-20 ma Analog Outputs, 6 Digital I/O s Z B C D Communications Options None MMI Software Compatible Std. Modbus Std Modbus and MMI Compatible Z Modem Communication None Z A B C Customized Configuration None Modbus Customization Complete System I/O Configuration Modbus + System I/O Configuration A B Sample Handling Rosemount Supplied Customer Supplied G A T D Z Z Z A A EXAMPLE Page 11

12 GCX INTEGRAL VAPOR PHASE SAMPLE HANDLING SYSTEM ORDERING INFORMATION SHVP GCX INTEGRAL VAPOR PHASE SAMPLE HANDLING SYSTEM Stream Number, Materials of Construction and Block/Bleed - Block/Vent Selections One Stream, One Cal. 316 SS, Viton Seals One Stream, One Cal. 316 SS, Kal Rez Seals -01 Add Block-to-Vent to the One Stream, One Cal. Selection Two Stream, One Cal, 316 SS, Viton Seals Two Stream, One Cal, 316 SS, Kal Rez Seals -01 Add Block-to-Vent to the Two Stream, One Cal. Selection -10 Add Block-&-Bleed to the Two Stream, One Cal. Selection -11 Add Block-&-Bleed and Block-to-Vent to the Two Stream, One Cal. Selection Three Stream, One Cal, 316 SS, Viton Seals Three Stream, One Cal, 316 SS, Kal Rez Seals -01 Add Block-to-Vent to the Three Stream, One Cal. Selection -10 Add Block-&-Bleed to the Three Stream, One Cal. Selection -11 Add Block-&-Bleed and Block-to-Vent to the Three Stream, One Cal. Selection Two Stream, Two Cal, 316 SS, Viton Seals Two Stream, Two Cal, 316 SS, Kal Rez Seals -01 Add Block-to-Vent to the Two Stream, Two Cal. Selection -10 Add Block-&-Bleed to the Two Stream, Two Cal. Selection -11 Add Block-&-Bleed and Block-to-Vent to the Two Stream, Two Cal. Selection Z S E Sample Handling System Heating Selection None Required Steam Heating Electric Heating SHVP Z EXAMPLE NOTE: Viton and Kal Rez are registered trademarks of E.I. dupont de Numours & Co., Inc. The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and conditions, which are available on request. We reserve the right to modify or improve the designs or specifications of our products at any time without notice. Rosemount Analytical Inc. Process Analytic Division 1201 North Main Street P.O. Box 901 Orrville, OH USA Phone Toll Free in US and Canada Fax GAS.CSC@frco.com Rosemount Analytical Inc., All rights reserved. Printed in U.S.A. on recycled paper.