Yokogawa GC1000 User Manual

User's Manual

GC1000 Mark II Process Gas Chromatograph Overview

IM 11B03A03-01E

3rd Edition

◆ Notice

● Regarding This Manual

1. This Manual should be passed on to the end user.

2. Read this manual carefully and fully understand how to operate this product before you start operation.

3. Y okogawa makes no warranty of any kind with regard to this material, but not limited to, implied warranties of merchantability for particular purpose.

5. Great effort has been expended to ensure that the descriptions in this manual are correct. Should you, however, come across a questionable area or note an inconsistency , a telephone call or letter to Yokogawa.co.,ltd. noting the questionable area would be highly appreciated.

6. The contents of this manual are subject to change without prior notice.

● Regarding Protection, Safety , and Prohibition Against Unauthorized Modifica-

tion.

1. For the protection and safe use of the product and the system controlled by it, be sure to follow the instructions on safety described in this manual when handling the product. In addition, if you handle the product in contradiction to these instructions, our company does not guarantee safety .

2. The following safety symbol marks are used on the product concerned or in this Manual :

WARNING

A WARNING sign denotes a hazard. It calls attention to procedure, practice, condition or the like, which, if not correctly performed or adhered to, could result in injury or death of personnel.

CAUTION

A CAUTION sign denotes a hazard. It calls attention to a procedure, practice, condition or the like, which, if not correctly performed or adhered to, could result in damage to or destruction of part or all of the product.

IMPORT ANT :

Indicates that operating the hardware or software in this manner may damage it or lead to system failure.

NOTE:

Draws attention to information essential for understanding the operation and features.

TIP:

Gives information that complements the present topic.

IM 11B03A03-01EMedia No. IM 11B03A03-01E 3rd Edition : Aug. 2006 (YK)

3rd Edition : Aug. 23. 2006-00

See Also:

Gives the reference locations for further information on the topic.

Protective ground terminal:

In order to provide protection against electrical shock in case of a fault. This symbol indicates that the terminal must be connected to ground prior to operation of equipment.

Function ground terminal:

In order to provide protection against noise. This symbol indicates that the terminal must be connected to ground prior to operation of equipment.

Alternating current

3. If protection / safety circuits are to be used for the product or the system controlled by

4. When you replace parts or consumables of the product, use those specified by our

5. Do not modify the product.

Indicates the power switch state “ON”.

Indicates the power switch state “Stand - by”.

Indicate the power switch state “OFF”.

it, they should be installed outside of the product.

company .

● Exemption from Responsibility

1. Y okogawa Electric Corporation does not make any warranties regarding the product except those mentioned in the WARRANTY that is provided separately.

2. Y okogawa Electric Corporation assumes no liability to any party for any loss or damage, direct or indirect, caused by the use or any unpredictable defect of the product.

● Regarding Software and set including Software Supplied by Y OKOGA WA

1. Y okogawa makes no other warranties expressed or implied except as provided in its warranty clause for software supplied Y okogawa.

2. Use this software with one specified computer only. Y ou must purchase another copy of the software for use with each additional com-

puter.

3. Copying this software for purposes other than backup is strictly prohibited.

4. Store the streamer or floppy disk (original medium) in a secure place.

5. Reverse engineering such as the disassembly of software is strictly prohibited.

6. No portion of the software supplied by Y okogawa may be transferred, exchanged, or sublet or leased for use by any third party without prior permission by Y okogawa.

IM 11B03A03-01E 3rd Edition : Aug. 23. 2006-00

◆ Warning/Caution Labels

● T o ensure safety operation of this equipment, warning/caution labels are at-

tached on the equipment as follows. Check these labels for your safety operation.

iii

[Left side] [Front] [Right side] [Back]

F0001.EPS

The inside of the enclosure is high temperature after turning off the power. Don’t touch the inside of the enclosure or the compponents, the protective gas should be suoolied for more than one hour after turning off the power.

F0002.EPS

IM 11B03A03-01E 3rd Edition : Aug. 23. 2006-00

◆ Introduction

Thank you for purchasing the GC1000 Mark II process gas chromatograph. This manual describes the technical information on overview of Model GC1000D /

GC1000S / GC1000T / GC1000E / GC1000W / GC1000C (Hereafter , it is abbreviated as GC1000 Mark II) Process Gas Chromatograph.

Please lead the following respective documents before installing and using the GC1000 Mark II system.

● Documents Related to the GC1000 Mark II Process Gas Chromatograph

1. Instruction manuals

The product comes with the following instruction manuals.

■ Instruction manuals that do not depend upon the specifications of the product

(1) Overview (IM 1 1B03A03-01E) (2) Basic Operation and Startup (IM 1 1B03A03-02E) (3) Maintenance and Inspection Manual (IM 1 1B03A03-04E)

(4) LCD Panel Operation Manual (IM 1 1B03A03-05E) (5) Alarm Message Manual (IM 1 1B03A03-06E) (6) Password Manual (IM 1 1B03A03-07E)

and Installation Manual (TI 1 1B03A03-13E)

■ Instruction manuals that depend upon the specifications of the product

(1) GCMT Gas Chromatograph Maintenance Terminal Software Package Operation

Guide (IM 1 1B03G03-03E)

(2) Capture It! Manual (IM 1 1B3G1-02E)

■ Instruction manuals for related products

(1) PCAS PC Analyzer Server Software (IM 11B06B01-01E) (2) ASET Analyzer Server Engineering Terminal Software (IM 1 1B06C01-01E) (3) GCET GC Engineering Terminal Software (IM 1 1B06D01-01E) (4) ASGW Analyzer Server Gateway Software (IM 11B06E01-01E) (5) ASIU Analyzer Server Interface Unit Software (IM 11B06F01-01E)

IM 11B03A03-01E 3rd Edition : Aug. 23. 2006-00

2. Operation Data

Operation data is supplied with the operation manuals in the delivered package and contains the following required to use the gas chromatographs.

● Process conditions and measurement range

● Instrument specifications and operating conditions

● Standard sample for calibration

● Column system and column

● Miscellaneous data

Chromatogram, base line, repeatability , power supply voltage variation, etc.

● Analyzer flow diagram and installation

● Parts composition table

● General connection diagram

● Sampling system diagram (only if supplied by Yokogawa)

● Is the System Ready?

Before reading this manual, the following preparations must have been completed.

● The system must be unpacked and installed in the correct place.

● The piping for the utility gases such as carrier and calibration gases must be completed, followed by leak checking.

● The wiring for the power supply and others must be completed.

If these have not been completed yet, see the Installation Manual (TI 1 1B03A03-13E). After completion, return to this manual and do the following:

● If the system power is on, turn off the power .

● Shut off all the gases at the flow control units.

Please read the following respective cautions (General Precautions, Caution of using Explosion-Protection Instruments, on Piping Construction, and on Piping Work) before installing and using the GC1000 system.

IM 11B03A03-01E 3rd Edition : Aug. 23. 2006-00

● General Precautions

WARNING

(1) In order to analyze gases, process gas chromatographs use a sample of the process

gas and utility gases.

Since these gases are typically combustible, combustion-sustaining, toxic, odorous, resolvable, polymerizing, or corrosive, refer to the “Safety Information” in our approval drawings and others to ensure safety thoroughly before using these analyzers.

(2) Up to two protection systems, each of which weighs approximately 10 kg, are installed

on top of the GC1000. Therefore, the center of gravity is higher than the center of the analyzer body .

Take great care when carrying and installing (piping- wiring) the GC1000. The GC1000 must be carried and installed very carefully (including piping and wiring) by more than one person (at least four people are recommended).

(3) Since the GC1000 are precision instruments, take care when handling not to jolt

of knock them.

(4) Use the GC1000 within the range of your purchase specifications.

Y okogawa assumes no responsibility for problems resulting from use by the customer outside the purchase specifications.

If the GC1000 need to be modified or repaired, please contact your nearest Y okogawa representative. Yokogawa assumes no responsibility for results where the customer or any third party has attempted to modify or repair these products.

(5) When touching LCD Panel switches

When touching LCD Panel switches, first, discharge Electro Static Charge of the body . Then, touch the LCD Panel switches. If not, LCD display may be changed by Electro

Static Discharge.

IMPORT ANT :

(1) Read the attached instruction manual before operating the GC1000 (2) The instruments must be installed and operated according to the installation manual,

instruction manual, approval drawings, and operation data.

IM 11B03A03-01E 3rd Edition : Aug. 23. 2006-00

● CA UTIONS OF USING EXPLOSION-PRO TECTION INSTR UMENTS

The GC1000 Process Gas Chromatographs are designed to protect against explosion. When these analyzers are used in a hazardous area, observe the following precautions.

Since the applicable standard differs depending on the specifications of the analyzer to be used, check the specifications of your analyzer.

(1) Kinds of explosion protection

To assure explosion protection, the GC1000 Process Gas Chromatographs have a pressurized and flameproof construction, or type X purging and explosionproof construction meeting the following standards :

• JIS Expd IIB + H2 T1 (programmed-temperature oven 320˚C max., isothermal oven 225˚C max., liquid-sample valve 250˚C max.)

• JIS Expd IIB + H2 T2 (programmed-temperature oven 225˚C max., isothermal oven 225˚C max., liquid-sample valve 225˚C max.)

• JIS Expd IIB + H2 T3 (programmed-temperature oven 145˚C max., isothermal oven 145˚C max., liquid-sample valve 145˚C max.)

vii

• JIS Expd IIB + H2 T4 (programmed-temperature oven 95˚C max., isothermal oven 95˚C max., liquid-sample valve 95˚C max.)

CENELEC (A TEX directive) certified : Group II Category 2G

• EEx pd II B +H2 T1 (programmed-temperature oven 320°C max, isothermal oven 225°C max., liquid-sample valve 250°C max.)

• EEx pd II B +H2 T2 (programmed-temperature oven 225°C max, isothermal oven 225°C max., liquid-sample valve 225°C max.)

• EEx pd II B +H2 T3 (programmed-temperature oven 145°C max, isothermal oven 145°C max., liquid-sample valve 145°C max.)

• EEx pd II B +H2 T4 (programmed-temperature oven 95°C max, isothermal oven 95°C max., liquid-sample valve 95°C max.)

FM Type X purging and Explosionproof for CLI, DIV1, GPS B, C & D, NEMA3R.

Type Y purging and Type X purging for CLI, DIV1, GPS.B, C & D, NEMA3R.

• T1 (programmed-temperature oven 320˚C max., isothermal oven 225˚C max., liquidsample valve 250˚C max.)

• T2 (programmed-temperature oven 225˚C max., isothermal oven 225˚C max., liquidsample valve 225˚C max.)

• T3 (programmed-temperature oven 145˚C max., isothermal oven 145˚C max., liquidsample valve 145˚C max.)

• T4 (programmed-temperature oven 95˚C max., isothermal oven 95˚C max., liquidsample valve 95˚C max.)

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CSA Type X purging and Explosionproof for CLI, DIV1, GPS B, C & D, NEMA3R.

Type Y purging and T ype X purging for CLI, DIV1, GPS.B, C & D, NEMA3R.

• T1 (programmed-temperature oven 320˚C max., isothermal oven 225˚C max., liquidsample valve 250˚C max.)

• T2 (programmed-temperature oven 225˚C max., isothermal oven 225˚C max., liquidsample valve 225˚C max.)

• T3 (programmed-temperature oven 145˚C max., isothermal oven 145˚C max., liquidsample valve 145˚C max.)

• T4 (programmed-temperature oven 95˚C max., isothermal oven 95˚C max., liquidsample valve 95˚C max.)

(2) Precautions for Explosionpr oof section (The analyzer with optional code "FM/CSA T ype Y purging" does not have the e xplosionproof section.)

When handling the screws on the cover of the Protection system, note the following to avoid damaging the screws since they cannot be repaired.

(1) The enclosure is pressurized. Before removing the cover, reduce the internal pres-

sure by loosening the sealing plug for wiring on the enclosure or relevant means.

viii

(2) When removing the cover, prevent any dirt or foreign matter from contaminating the

screw part.

(3) When installing the cover, tighten the screws by hand ; never use tools. (4) Since the screws are coated with MOL YKOTE, do not lubricate them.

(3) Precautions when using hydrogen gas

When using hydrogen gas as the carrier gas, the FID or FPD combustion gas, to ensure safety , install the analyzer in a location equipped with a ventilator or where there is sufficient ventilation. Make sure there are no gas leaks from the pipe joints and inspect for leaks.

(4) Installation site and environment

The analyzer specifications allow it to be used in hazardous areas as defined by Zone1 IIB + H

, T2, T3, T4 (JIS / CENELEC) or DIV1, GPS B, C & D, T1, T2, T3, T4 (FM / CSA).

2T1

However, never install the analyzer in an area where the density of explosive gas persists for a long time.

(5) Wiring works

Model GC1000D / GC1000S, analyzer obtains explosion proof authorization by the complete set including metal fittings of the attachment.

When performing wiring, always use the attached sealing fittings and flameproof packing adapter.

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(6) Maintenance and inspection

During usual maintenance and inspection, it is not necessary to check the explosionprotected section.

Before opening the door of the explosion-protected section for maintenance and inspection, be sure to turn off the power . After completing maintenance and checks, close the door completely then turn on the power after checking that the specified explosion protection performance is guaranteed. The parts to be checked are described in the Maintenance and Inspection Manual (IM 1 1B03A03 - 04E).

If any of the following damage occurs, contact a Yokogawa sales representative or the Y okogawa sales division

(1) If the screws securing the Protection System (explosionproof construction) are dam-

aged

(2) If the exterior or light transmission section of the enclosures is damaged (3) If packings are cracked or conspicuously deformed

(7) Override function (The analyzer with optional code "FM/CSA T ype Y purg ing" does not have this function.)

WARNING

• When the override function is used, Analyzer becomes an ignition source and the high temperature and the high voltage part will be exposed.

• Please confirm that in the ambient atmosphere, the concentration of explosive gases is less than the allowable limit, by using a gas detector.

To return to the normal operation, turn off “the override switch” and then close the door as it was before turning on power.

In this analyzer, if the pressure of the pressurized / type X purged enclosure system (oven, electronic section) drops while the power is on, the pressurized explosion protection section is activated to stop power supply . Therefore, in case of opening the door of the oven or of the electronic section inadvertently , for maintenance, while the power is on, the protection system is activated to cut off the power .

The “override function” intensively releases this function of protection system.

The override switch is installed in section.

(8) Replacing parts

Always use parts specified by Yokogawa when replacing parts, for replacement, refer to the Maintenance and Inspection Manual (IM 1 1B03A03 - 04E).

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(9) Operation

WARNING

* Only trained persons may use this instrument in a hazardousl location. * Do not open when energized.

<FM>

For type X purging:

* This equipment contains components that operate at high temperature. The equip-

ment shall be deenergized for 60 minutes to permit those components to cool before the enclosure is opened unless the area is demonstrated to be nonhazardous at the time.

* Enclosure shall not be opened unless the area is known to be nonhazardous, or

unless all devices within have been de-energized.

* Power shall not be restored after enclosure has been opened until enclosure has

been purged for 12 minutes. (When the internal pressure is restored, the system automatically purges over the 12 minutes, then turns on the power again.)

For explosionproof enclosure:

* Seal all conduits within 18 inches * Open circuit before removing cover.

For type Y purging:

* Enclosure shall not be opened unless the area is known to be non-hazardous, or

unless all devices within have been de-energized. Power shall not be restored after enclosure has been opened until enclosure has been purged for 12 minutes at specified pressure indicated by the pressure gauge labeled “EL.BOX” in the pressure and flow control section.

* Alarm shall be provided and connected to alarm contact output.

(a) The alarm shall generate a visual or audible signal that attracts attention (b) The alarm shall be located at constantly attended location. (c) Electrical alarms shall be approved for the location in which they are installed.

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<CSA>

For type X purging:

* This equipment contains components that operate at high temperature. The equip-

ment shall be deenergized for 60 minutes to permit those components to cool before the enclosure is opened unless the area is demonstrated to be nonhazardous at the time.

* Enclosure shall not be opened unless the area is known to be non-hazardous, or

unless all devices within the enclosure have been de-energized. Power must not be restored after enclosure has been opened until enclosure has been purged for 12 minutes at a flow rate of 0.05m

* Power will automatically be removed when purge pressure falls below 40 mm (1.6 in)

of water column.

For explosionproof enclosure:

* A seal shall be installed within 50 cm of the enclosure. * Open circuit before removing cover.

For type Y purging:

* Enclosure shall not be opened unless the area is known to be non-hazardous, or

unless all devices within the enclosure have been de-energized. Power must not be restored after enclosure has been opened until enclosure has been purged for 12 minutes at a flow rate of 0.05m

/min.

/minute min.

* Remove power below 40mm (1.6in) of water column.

Take care not to generate mechanical spark when accessing to the instrument and peripheral devices in hazardous locations.

Do not press prick the keyboard of LCD panel (operation and display section) using such as knives and sticks.

(10) Maintenance and Repair

The instrument modification or parts replacement by other than authorized representative of Yokogawa Electric Corporation is prohibited and will void the approval of Factory Mutual Research Corporation and CSA certification and CENELEC certification .

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3rd Edition : Aug. 23. 2006-00

● Precautions Against Electrostatic Pr oblems

The GC1000 system uses numerous IC components. When handling cards with IC components mounted on them for maintenance or setting changes, take full precautions against electrostatic problems.

These precautions are summarized below. (a) When storing or carrying cards, enclose them in a conductive bag or antistatic

bag. (Cards as shipped by Yokogawa are enclosed in a conductive bag or antistatic bag labeled with cautions against electrostatic problems.)

(b) Whenever mounting or demounting cards into or from a product, wear a wrist

strap grounded via a 1 MΩ resistance. Connect the wrist strap to any ground terminal near the ground wire or to any unpainted part of the grounded frame.

xii

List strap

Sheet

1M‰

Using a wrist strap and conductive sheet Using a Conductive Sheet

Gard

List strap

F0003.EPS

grounded via a 1 MΩ resistance, wearing a wrist strap as in (2) above. Keep easily-chargeable plastic materials away from the bench.

(d) Never touch components mounted on the cards, the pattern side, connectors,

pin components, etc. with bare hands, unless using a wrist strap and a conductive sheet.

(e) Wrist straps and conductive sheets are available from Yokogawa Engineering

Service (YSV).

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3rd Edition : Aug. 23. 2006-00

GC1000 Mark II Process Gas Chromatograph Overview

CONTENTS

◆ Notice .......................................................................................................... i

◆ W arning/Caution Labels............................................................................iii

◆ Introduction ...............................................................................................iv

1. Principle of Gas Chr omatograph ........................................................... 1-1

1.1 Sampling Mechanism ..................................................................................... 1-1

1.2 Component Separation Using Column.......................................................... 1-2

1.3 Detector ........................................................................................................... 1-3

2. Terminology ............................................................................................ 2-1

Toc-1

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2.1 Operation Terminology ................................................................................... 2-1

2.2 Instrument Terminology.................................................................................. 2-2

3. System Configuration ............................................................................ 3-1

3.1 T ype and Appearance..................................................................................... 3-1

3.2 Components and Their Functions.................................................................. 3-2

3.2.1. Protection System ............................................................................ 3-2

3.2.2 Electronic Section............................................................................. 3-2

3.2.3 Pressure and Flow Control Section................................................... 3-2

3.2.4 Isothermal Oven ............................................................................... 3-2

3.2.5 Programmed-temperature Oven ....................................................... 3-3

3.2.6 Analyzer Base Sampling Section ...................................................... 3-3

3.3 Block Diagram................................................................................................. 3-4

3.4 Internal Piping System Diagram .................................................................... 3-7

3.5 External Input and Output Signals............................................................... 3-12

4. Outline of Software................................................................................. 4-1

4.1 Status and Operation Mode............................................................................ 4-1

4.1.1 Process ............................................................................................ 4-2

4.1.2 Manual ............................................................................................. 4-5

4.1.3 Lab ................................................................................................... 4-5

4.2 Stream ............................................................................................................. 4-6

4.3 Method............................................................................................................. 4-7

4.4 Description of Actions.................................................................................... 4-9

4.4.1 Actions of Stream Sequence........................................................... 4-10

4.4.2 Actions of Stream (Continuous) .......................................................4-11

4.4.3 Actions of Stream (1 cycle) ............................................................. 4-13

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5. Actions of External Input and Output Signals ....................................... 5-1

Toc-2

4.4.4 Actions of Calibration...................................................................... 4-14

4.4.5 Actions of V alidation........................................................................ 4-17

4.5 Computation and Processing ...................................................................... 4-20

4.5.1 Peak Processing............................................................................. 4-20

4.5.2 Deviation processing ...................................................................... 4-20

4.5.3 Additional processing...................................................................... 4-20

4.5.4 Signal Processing........................................................................... 4-21

4.6 Alarm Processing ......................................................................................... 4-22

5.1 Analog Hold Output ........................................................................................ 5-1

5.1.1 When Actual Stream is Specified for Stream Number (without Stream

Identification Signal) ......................................................................... 5-2

5.1.2 When Actual Stream is Specified for Stream Number (with Stream

Identification Signal) ......................................................................... 5-3

5.1.3 When "99" is Specified for Stream Number (with Stream Identification

Signal) .............................................................................................. 5-4

5.2 Contact Output................................................................................................ 5-5

5.2.1 Stream Sequence............................................................................. 5-5

5.2.2 Stream.............................................................................................. 5-6

5.2.3 Operation Mode................................................................................ 5-6

5.2.4 Alarm................................................................................................ 5-6

5.2.5 Timing............................................................................................... 5-6

5.3 Contact Input................................................................................................... 5-7

5.4 Communication Input and Output ................................................................. 5-8

5.4.1 GC6 T ype Output Data Format (Fixed to 45 Characters)................... 5-8

5.4.2 GC6 T ype Input Data Format ............................................................ 5-9

5.4.3 GC8/GC1000 Type Output Data Format (Fixed to 45 Characters)....5-1 1

5.4.4 GC8/GC1000 T ype Input Data Format............................................ 5-12

5.4.5 MODBUS Communication Data Specification................................. 5-14

◆ Revision Record ......................................................................................... i

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3rd Edition : Aug. 23. 2006-00

1. Principle of Gas Chromatograph

A gas chromatograph is an analyzer which first sends a fixed volume of the sampled multicomponent gas mixture to a column, separates it in the column, then measures the concentrations of the components with a detector. The process gas chromatograph analyzes intermittently , allowing periodic analysis in a specified sequence, thus automatic sampling is possible.

This chapter explains the measurement principle of the GC1000 Process Gas Chromatographs.

1.1 Sampling Mechanism

The process gas chromatograph consists of a sampling mechanism, a column and a detector.

Sampling is carried out by switching a sampling valve. When separating components or detecting concentrations, the sampling valve is set to allow the gas (liquid) to be measured to flow through the sample column. When sampling, the sampling valve leads the gas (liquid) to be measured to a column on a carrier gas. (See Figure1.1)

There are two important points regarding sampling: a regular volume is sampled since repeated sampling is required; and samples are taken quickly and securely . The volume is fixed by measuring a specific gas (liquid) of controlled temperature and pressure using a sample measurement tube. Samples are taken quickly and securely by ensuring that the gas to be measured always flows without interrupt.

1-1

Sample

Carrier gas

Sample

Carrier gas

Component separation and

concentration detection

Measuring tube

Sample valve

Vent

Column Detector

Electric signal

Status of sampling

Measuring tube

Sample valve

Vent

Column Detector

Electric signal

Figure 1.1 Basic Configuration of Gas Chromatograph

F0101.EPS

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1.2 Component Separation Using Column

Three types of columns are available for the GC1000 Process Gas Chromatographs: the packed column, the mega-bore column and the capillary column.

The packed column consists of a stainless pipe, 2 mm in diameter and 0.2 to 2.0 m in length and filled with a bulking agent called a stationary phase.

The mega-bore and capillary columns, of approximate diameter 0.5 mm and 0.3 mm respectively , are coated inside a certain phase called a stationary phase.

The components in the multi-component gas mixture sample with carrier gas, which called mobil phase move through the column, repeatedly absorbing the stationary phase and dissolving from the stationary phase at a certain cyclic rate conforming to a fixed partition coefficient * that is unique to each component.

Since the transfer rates differ depending on the partition coefficient, a multi-component gas mixture gradually separates into discrete components and is separated in the order of the transfer rates.

* Partition coefficient : The concentration ratio of the components, calculated by dividing the component concentration which

is in equilibrium in the stationary phase by the concentration which is in equilibrium in the mobile phase.

Figure 1.2 shows a diagram of how the multi-component gas mixture is led to a column and separated into its discrete components over time.

1-2

Multi-component gas mixture

Sampling

(1st round)

Time

(2nd round)

Figure 1.2 Separating Components Using a Column

(Intake) (Outlet)Column

Injection

:Component A, :Component B, :Component C

Detector Concentration signal

Carrier gas

F0102.EPS

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1.3 Detector

The components separated in the column are led to the detector where the concentration of each component is measured.

The GC1000 Process Gas Chromatographs can be fitted with thermal conductivity detectors (TCD), flame ionization detectors (FID) or flame photometric detectors (FPD). The thermal conductivity detector can measure almost all non-corrosive components but sensitivity is relatively low. On the other hand, the hydrogen flame ionization detector can measure hydrocarbon and the flame photometric detector can measure sulfur compounds, respectively with high sensitivity .

(1)Thermal Conductivity Detector (TCD)

The TCD utilizes the difference in the thermal conductivity between the measured gas and the carrier gas and detects the unbalanced voltage produced in a bridge circuit as a measure of concentration.

Figure 1.3 shows the fundamental principle of the TCD. As shown, there are two streams, each having two filaments. One stream passes the carrier gas only and the other, connected to the column outlet, allows the measured gas to pass during analysis. The filaments in the two streams form a bridge circuit such that the filament in one stream is adjacent to the filament in the other stream. The unbalanced voltage in the bridge is proportional to the concentration of the measured gas (liquid) component.

1-3

The TCD is frequently used to measure the component concentration of the measured gas (liquid).

Carrier gas

Figure 1.3 Fundamental Principle of Thermal Conductivity Detector

Comparison filament

Measurment filament

Carrier gas

Sampling gas

Z1 Z2

Z4 Z3

Constant voltage

Measurment filament

Comparison filament

Output

F0103.EPS

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(2)Flame Ionization Detector (FID)

The FID utilizes the phenomenon that carbon molecules in the measured component (hydrocarbon) are ionized in a hot hydrogen flame. That is, it detects the ionization current which flows between electrodes to which a high voltage is applied. The ionization current is proportional to the concentration of the measured component.

The FID is used to measure the component concentration of gases containing low concentrations of hydrocarbons.

Ion collector coil

Hydrogen flame

Jet pipe (nozzle)

Output

1-4

Carrier gas

Sampling gas

Figure 1.4 Fundamental Principle of Flame Ionization Detector

(3)Flame Photometric Detector (FPD)

Figure 1.5 shows the structure of the FPD. As the sample gas containing a sulfur component is led into the excess hydrogen flame, the component containing the sulfur atoms is excited. The FPD detects the luminous intensity of the light emitted when this excited component return to its base state using multiplier phototube and converts it to a voltage. This voltage represents the concentration of the sulfur component in the measured gas.

The FPD can measure on the sulfur component with a high sensitivity of 1 ppm.

Hydrogen flame

Jet pipe (nozzle)

Hydrogen gas for combustion

Carrier gas

Sampling gas

Figure 1.5 Basic Configuration of Flame Photometric Detector

Photomultiplier tube

Hydrogen gas for combustion

F0104.EPS

Hydrogen gas for combustion

Air fo combustion

F0105.EPS

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2. Terminology

2.1 Operation Terminology

Term Description Notes

Remote Mode

Local Mode

Status

Process Manual Lab

Operation Mode

Run Pause Stop

Measurement Status

Stream Sequence Stream (continuous) Stream (1 cycle) Calibration

Validation Method Analysis Cycle Warming Up Time Peak Detection Stop Time Pause Time Purging

Status accessible without password, LCD/key: used only for reference GCMT: connectable Status accessible by entering password LCD/key: used for changing settings

Normal measurement and calibration Manual operation Measurement with automatic peak detection, like a lab GC

Mode in which measurement is running Mode in which measurement pauses Mode in which measurement stops

Continuously measures streams in order specified in Stream Sequence Continuously measures the specified stream Measures the specified stream once Performs calibration of the specified number Performs validation of the specified number Configures action timing of various valves and other parameters Time from start (0 second) to stop of analysis Time for displacement in sample streams Time to stop peak detection of chromatogram compulsorily Time for measurement pause Displacement of the gas in the pressurized/Type X purged enclosures with a protection gas

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T0201.EPS

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2.2 Instrument Terminology

Term Explanation Notes

TCD FID FPD LSV Restrictor Methane converter Sampling valve Back-flush valve Column switching valve Atmospheric-pressure balancing

valve Protection gas

Flame arrester Splitter Pressurized enclosure Temperature protection circuit Protection device

EPC

A thermal conductivity detector A flame ionization detector A flame photometric detector A liquid sampling valve A variable resistor A methane reaction system : Methanizer A valve for inputting samples A switching valve for back flush A valve for switching between columns A balancing valve for sampling gases

Air A device for protecting against "flame runaway" A flow splitter An enclosure whose internal pressure is kept high with protection gas A circuit for turning off the heater to prevent overheating A device for detecting a pressure drop in the analyzer to shut down the power supply

Electric pressure controller

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T0202.EPS

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3. System Configuration

3.1 T ype and Appearance

The GC1000 Process Gas Chromatographs consist of (A) a protection system, (B) an electronic section, (C) a pressure and flow control section, (D) an isothermal oven, (E) a programmed-temperature oven (GC1000D / GC1000T / GC1000W) and (F) an analyzer base sampling section (see Figure 3.1).

Note: There are two types of analyzer base sampling section, either the built-in type within GC1000 (the sample processor is

embedded), or the external type (the sample processor is separate). Select the type best suited to the intended usage.

Display Explosion proof enclosures

(number depends on specifications)

(A) Protection system

(B) Electronic section

Terminal section

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(D) Isothermal oven (E) Programmed-temperature oven

(F) Analyzer base

sampling section

(Note)

Figure 3.1Analyzer Components

EPC box (in the case that EPC is installed)

F0301.EPS

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3.2 Components and Their Functions

3.2.1. Protection System

The protection system has a explosion-proof construction and is equipped with a built-in protection circuit. The power relay , pressure switch, timer , relays, override switch, etc. are internal to the instrument. The override function is particularly important for maintenance, since it allows the power to be turned on even if there is an internal pressure loss. The system monitors the internal pressures of the electronic section, isothermal oven and the programmed-temperature oven (GC1000D / GC1000T / GC1000W), and if any of them indicates an internal pressure lower than 392 Pa, it shuts down the power supply to those components. After a power shut-down, when the internal pressure is restored, the system automatically purges over the 12 minutes, then turns on the power again. Analyzers of nonexplosion-proof type and with FM/CSA T ype Y purging do not have this protection system.

3.2.2 Electronic Section

The electronic section has a pressurized protection/Type X purged structure and is designed for control of a detector, an isothermal oven, various valves and others, for processing and computation, and for output of the results. The LCD and operation keys on the front of the electronic section allow manual operation of the GC1000 Mark II.

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3.2.3 Pressure and Flow Control Section

The pressure and flow control sections control and indicate the pressures of sample gases, standard gases, carrier gases, FID or FPD hydrogen (or nitrogen) for combustion, or FID or FPD air for combustion. Regulator values or EPC is installed. It also contains pressurereducing valves for controlling purge gases, the air for actuating valves or the vortex tube, an air-actuated valve for balancing atmospheric pressure, a vortex tube and a hydrogen restriction system.

3.2.4 Isothermal Oven

The isothermal oven has an pressurized protection / T ype X purged structure. The temperature is set at a fixed level from 55 to 225°C (setting by 1°C unit). The isothermal oven contains valves such as the sample valve which is air-activated, the back flush valve, the column for separating a multi-component gas mixture into its individual components and leading the components to the detector in sequence, the detector for detecting the components, and the restrictor for controlling the gas flow rate, etc.

There are three types of detector, the thermal conductivity detector (TCD), the flame ionization detector (FID) and the flame photometric detector (FPD); either one or two of these detectors can be used simultaneously (however, the FPD can only be installed in the combustion chamber).

The component signals picked up by the detector are led to the electronic section for signal processing.

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3.2.5 Programmed-temperature Oven

The programmed-temperature oven has an internal pressure protection / T ype X purged structure. It contains a column that separates multi-component mixture samples into individual components and leads them to the detector in sequence. The temperature can be set to a fixed setting or it can be programmed. The allowable temperature range is 60 to 320°C without a cooling system, or 5 to 320°C with a cooling system, and the temperature can be set to rise from between 0.1 to 30°C/min (setting by 0.1°C unit). Up to three temperature-rise patterns can be programmed.

3.2.6 Analyzer Base Sampling Section

The analyzer base sampling section is equipped with sample and standard gas streams, and controls the sample pressure and flow rate. It also selectively sends the sample to be analyzed in a stream, and can switch the standard gas to the isothermal or the programmed-temperature oven by a valve depending on the signal sent from the electronic section.

If the analyzer does not contain the analyzer base sampling section, then samples can be processed externally by supplying air to a separate sampling section.

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