RMG PGC 9300 Operating Manual
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RMG PGC 9300 Operating Manual

Measuring element
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PGC 9300 – Measuring Element
Reliable Measurement of Gas
Status:
June, 18th 2018
Version:
07
OPERATING MANUAL

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Summary of Contents for RMG PGC 9300

  • Page 1 PGC 9300 – Measuring Element OPERATING MANUAL Reliable Measurement of Gas Status: June, 18th 2018 Version:...
  • Page 2 Translation of the The PGC9300_ME_manual_en_07 for the gas chromato- original document graph PGC 9300 from June, 18th 2018 is a translation of the original German manual. Anyhow, this document may serve as reference for translations into other languages. Remark: Please use in case of any uncertainties the German ver- sion as main reference.

  • Page 3: Table Of Contents

    2 QUICK GUIDE ..................26 Mechanical connection ..................26 Electrical connection ..................28 Commissioning ....................28 3 GAS CHROMATOGRAPH PGC 9300 ..........29 Type designation ....................29 Mode of operation ....................31 Configuration of the measuring element unit ..........33 Gas flow distribution ..................
  • Page 4 Appendix 2 A: Error during operation ..............68 Appendix 2 B: Errors during recalibration .............. 69 Appendix 2 C: Mains failure of the GC 9300 ............69 APPENDIX 3: PRE-FILTER FLUSHING UNIT ........70 APPENDIX 4: CERTIFICATES ..............75 Manual PGC 9300 EN07 June, 18th 2018...

  • Page 5: About This Manual

    The third part of the introduction describes recurrent inspection and maintenance tasks. Since the PGC 9300 “consumes” gases in order to be able to conduct an analysis of the gas components, these regular maintenance tasks are necessary for the proper function of the PGC 9300.

  • Page 6: Objective Of This Manual

    How- ever, its use can entail dangers that can be avoided by complying with this man- ual. The gas chromatograph PGC 9300 must only be used as intended and in technically sound condition.

  • Page 7: Working With The Device

    Disregard of the safety notices can result in danger to the life and limb or environ- mental and property damage. Bear in mind that the safety warnings in this manual and on the device cannot cover all potential dangerous situations, because the interaction of various condi- Manual PGC 9300 EN07 June, 18th 2018...
  • Page 8 (Appendix 1: Technical data). Performance limits must not be ex- ceeded. • For safe operation, the gas chromatograph PGC 9300 must only be used in the scope of the intended use (Chapter 3 Gas chromatograph PGC 9300 and 3.8 Area of applicability)
  • Page 9 1 About this manual • The PGC 9300 complies with current standards and regulations. However, danger can arise with misuse and the measuring element of the PGC 9300 can be destroyed due to operator error. 1.2.4.2 Dangers during commissioning Initial commissioning...
  • Page 10 Connection of pressurized pipelines must only be carried out by trained qualified personnel. Observe the following: • Proof of competence of trained qualified personnel and the RMG test report of solder-free pipe fittings must be submitted by the installation company for the commissioning.
  • Page 11 1 About this manual • Anchor the PGC 9300 on the floor to ensure that it is stable. For this pur- pose, use clamps or brackets to fasten it to the floor. There are fastening eyes in the rear of the feet to accommodate mounting on the wall or a ground beam.
  • Page 12 The gas chromatograph PGC 9300 must only be used as intended! (Chapter 3 Gas chromatograph PGC 9300 and 3.8 Area of applicability). Prevent use of the gas chromatograph PGC 9300 as a potential climbing aid or use of attachments of the PGC 9300 as potential handles! 1.2.4.4...

  • Page 13: Risk Assessment And Minimization

    According to assessment by qualified employees of RMG, the gas chromatograph PGC 9300 is subject to risks during its use. Risks can also arise due to high pres- sures and occasionally due to pressures that are too low. Work outside of the per- missible temperature range can also lead to dangers.

  • Page 14: Validity Of The Manual

    This manual describes the gas chromatograph PGC 9300. The gas chromato- graph PGC 9300 is only part of a complete system. The manuals of the other compo- nents of the system must be observed, too. If you find contradictory instructions, contact RMG and/or the manufacturers of the other components.

  • Page 15: Transport

    Instruct your personnel with regard to the risks involved with working with the device. Suitable personal protective equipment must be used for work on the PGC 9300 that you, as the operator, must provide. This applies despite the fact that all sharp edges on the device were removed as far as possible.

  • Page 16: Scope Of Delivery

    1 About this manual • Transport must only take place with the device lying on its back • Transport the PGC 9300 secured on a pallet with wedges and tensioning belts, secured against movement and toppling over • If you suspect that transport has taken place incorrectly or that damage has...

  • Page 17: Disposal Of Packaging Material

    RMG. However, if storage is necessary, the following must be observed: • The PGC 9300 must be positioned upright after it has been unloaded • The PGC 9300 must be secured against movement and tipping over • Storage in an air-conditioned and dry environment is required due to the sensitivity to moisture •...
  • Page 18 1 About this manual Interruption of the carrier gas supply • Any form of improper storage can result in damage and necessitate a new factory calibration Manual PGC 9300 EN07 June, 18th 2018...

  • Page 19: Explosion-Proof Design

    The device conforms to the requirements of Directive 94/9/EC. Danger The PGC 9300 is permitted for installation in explosion-prone areas in Zone 1 that are endangered by gas and vapor assigned to explosion group IIB+H and temperature class T4 or T5.

  • Page 20: Connection Housing With Elevated Safety

    Unused openings for cable input must be sealed with shockproof sealing plugs secured from independently loosening and turning. When sealing, it must be ensured that the seals remain effective in order to maintain the IP 54 protection rating. Manual PGC 9300 EN07 June, 18th 2018...

  • Page 21: Inspection And Maintenance Tasks

    Note Manual, book of maintenance logs, acceptance inspection certificate and test logs must remain accessible within the vicinity of the PGC 9300 and always readily available (see also chapter 1.2.4.2 Dangers during commis- sioning).
  • Page 22 (chapter 1.2.4.4 Qualification of ). If repairs are carried out by the manufacturer, acceptance by a qualified expert is not necessary. Manual PGC 9300 EN07 June, 18th 2018...

  • Page 23: Draining Condensate From The Measuring Element

    However, if this should occur, the measuring element switches off auto- matically in the range between 2 and 3 bar. Manual PGC 9300 EN07 June, 18th 2018...
  • Page 24 Set the selector switch to cylinder B (arrow points to cylinder B) to re- place cylinder A! Close the cylinder valve of A and extraction valve 2A. Open vent valve 1A and close it again after pressure equalization. Manual PGC 9300 EN07 June, 18th 2018...
  • Page 25 Re-tighten the screw connection on the carrier gas inlet of the PGC. Check all lines to ensure that there are no leaks. Use the selector switch to select the cylinder that should be used for ex- traction during operation. Manual PGC 9300 EN07 June, 18th 2018...

  • Page 26: Replacing The Carrier Gas Filter

    / hydrogen measurement (Figure 6: Gas chromatograph PGC 9300, Pos. 6). It is a moisture filter that filters water out of the carrier gas. The filter can be obtained from RMG as spare part; the type designation is:...
  • Page 27 The service department must be contacted in this case. Caution We urgently recommend contacting RMG customer service to replace the filter on the PGC 9300 in order to minimize the risk of damage to the meas- uring element. Manual PGC 9300 EN07 June, 18th 2018...
  • Page 28 13. Wait at least 6 hours until the measuring ele- ment has been flushed. Caution An inadequate flushing time can result in irreparable damage to the measuring element! Manual PGC 9300 EN07 June, 18th 2018...
  • Page 29 The saturated filter is special waste and must be disposed of according to statutory specifications. Appendix 3: Pre-filter flushing unit describes how simple replacement with reduced maintenance times can be realized with 2 filter units. Manual PGC 9300 EN07 June, 18th 2018...

  • Page 30: Quick Guide

    2.1 Mechanical connection The supply lines for connections A - M ((Figure 6: Gas chromatograph PGC 9300) are designed as 1/8” pipelines with a compression fitting connection. Appropriate particle filters are arranged upstream from the analytical device. The lines should be stainless steel and free from soiling, grease, solvents, etc.
  • Page 31 The “Normal Calib.” operating mode must be selected after compensation of the input pressures. The chromatograph performs a calibration cycle. The PGC 9300 automatically switches to “Autorun” mode after successful calibra- tion. Please read chapter 4.5 Interruption of the carrier gas supply for details about in- terrupting the carrier gas supply.

  • Page 32: Electrical Connection

    9.5 – 15.9 mm For recommended cable types, refer to chapter 4.1 Electrical connections. 2.3 Commissioning Commissioning normally takes place together with the controller. For this purpose, read the manual of the GC 9300 (PGC9300_AC_manual_en_12). Manual PGC 9300 EN07 June, 18th 2018...

  • Page 33: Gas Chromatograph Pgc 9300

    This other, separate evaluation unit is the GC 9300, which determines the course of the analysis and provides measurement results as an evaluation unit and control computer. The PGC 9300 is always oper- ated together with the GC 9300.
  • Page 34 , CO PGC 9305 Natural gas B (helium carrier gas) to C * The chronological sequence of the components corresponds to the sequence of the list. Table 1: Properties of the PGC 930X versions Manual PGC 9300 EN07 June, 18th 2018...

  • Page 35: Mode Of Operation

    As a result, all of the components arrive at the end of the column at different times. Manual PGC 9300 EN07 June, 18th 2018...
  • Page 36 The further evaluation of the area share takes place in the analytical computer GC 9300. If the PGC 9300 is used as a multi-streamer and requires more than 2 DSfG bus connections, they can be provided with a gateway, the GC 9310. This can be seen in Figure 5: Separation of Ex zones to the left above the analytical computer GC 9300.

  • Page 37: Configuration Of The Measuring Element Unit

    (calibration interval = 1 day), but other intervals can be adjusted, too. The PGC 9300 can be designed as a single stream unit for analysis of the gas from one extraction point or as a multi-stream unit for up to four extraction points.
  • Page 38 • The actual chromatograph is placed in a pressure-proof encapsulated housing (1). This compact unit comprises the separating columns, heating, injectors, detectors, pressure regulation, data recording hardware and communication hardware. The housing is heated in order to maintain the necessary internal temperature. Manual PGC 9300 EN07 June, 18th 2018...
  • Page 39 4.) Gas inlet module from the left with filter plate in pipe (basic version) Option: 5.) Inlet filter carrier gas 6.) Membrane filter unit with condensate collectors (hand valve) for sample gases Total weight: approx. 75 kg Figure 6: Gas chromatograph PGC 9300 Manual PGC 9300 EN07 June, 18th 2018...

  • Page 40: Gas Flow Distribution

    2. calibration gas 6. sample gas outlet 2. Kalibriergas 6. Analysengas 3. test gas 7. off gas 3. Referenzgas 7. Entlüftung 4. safe shut off valve 4. Magnetventil Figure 7: Gas (distribution principle diagram) Manual PGC 9300 EN07 June, 18th 2018...

  • Page 41: Gas Chromatograph

    The main board is re- sponsible for the evaluation of the chromatogram and for the transmission of all measurement data to the analytical computer. Manual PGC 9300 EN07 June, 18th 2018...
  • Page 42 3 Gas chromatograph PGC 9300 Analysis modules Solenoid valve Pressure regulator Pressure transmitter Ex d enclosure Figure 8: Gas distribution (photo) Manual PGC 9300 EN07 June, 18th 2018...
  • Page 43 3 Gas chromatograph PGC 9300 Analysis modules Main board Power supply Column pressure regulation Column electronics Figure 9: Functional blocks Manual PGC 9300 EN07 June, 18th 2018...

  • Page 44: Analysis Process

    The gas stream flows through the sample loop. Continuous flushing that is always activated takes place at the PGC 9300. Figure 10: Flushing (default position) Manual PGC 9300 EN07 June, 18th 2018...
  • Page 45 REFERENCE COLUMN INJECTION CARRIER GAS 5.5bar SAMPLE COLUMN SAMPLE CARRIER GAS PRESSURE INJECTION REGULATOR SWITCH SAMPLE LOOP SAMPLE VENT SAMPLE CARRIER GAS 5.5bar SAMPLE IN CARRIER GAS REGULATED SAMPLE Figure 11: Application of pressure Manual PGC 9300 EN07 June, 18th 2018...
  • Page 46 REFERENCE COLUMN INJECTION CARRIER GAS 5.5bar SAMPLE COLUMN SAMPLE CARRIER GAS PRESSURE INJECTION REGULATOR SWITCH SAMPLE LOOP SAMPLE VENT SAMPLE CARRIER GAS 5.5bar SAMPLE IN CARRIER GAS REGULATED SAMPLE Figure 12: Injection Manual PGC 9300 EN07 June, 18th 2018...
  • Page 47 REFERENCE COLUMN INJECTION CARRIER GAS 5.5bar SAMPLE COLUMN SAMPLE CARRIER GAS PRESSURE INJECTION REGULATOR SWITCH SAMPLE LOOP SAMPLE VENT SAMPLE CARRIER GAS 5.5bar SAMPLE IN CARRIER GAS REGULATED SAMPLE Figure 13: Analysis Manual PGC 9300 EN07 June, 18th 2018...

  • Page 48: Separating Columns

    The process sequence shown in Figure 7: Gas (distribution principle diagram) ap- plies for all channels. 3.8 Area of applicability The PGC 9300 is normally operated in an Ex d housing in Ex Zone 1. Safety classification: II 2G Ex db e IIB+H T5 (<...

  • Page 49: Manual Pgc 9300 En07 June, 18Th

    The measuring gas pressure is set to 1 bar at the factory. The pressure defined at the gas distribution must then be kept within a tolerance range. Measurement and monitoring also take place via the analytical computer. Manual PGC 9300 EN07 June, 18th 2018...

  • Page 50: Required Gases And Gas Consumption

    1.00 Iso-butane 0.20 0.20 0.20 n-butane 0.20 0.20 0.20 neo-pentane 0.05 0.00 0.00 iso-pentane 0.05 0.00 0.05 n-pentane 0.05 0.00 0.05 n-hexane 0.05 0.00 0.05 Oxygen 0.00 0.40 0.50 Hydrogen 0.00 0.20 1.00 Manual PGC 9300 EN07 June, 18th 2018...

  • Page 51: Sample Gas

    Liquid components and other impurities are not permitted. The values specified under 3.10.1 and 3.10.2 apply for the inlet pressure and gas consumption. The working range of the modules is within the following limit values: Manual PGC 9300 EN07 June, 18th 2018...
  • Page 52 The oxygen is recognized and shown together with nitrogen without Column C. The limit values are monitored by the analytical computer. Note The limit values on the type plate apply in calibrated operation. Manual PGC 9300 EN07 June, 18th 2018...

  • Page 53: Connection And Commissioning

    The electrical connections must be made as specified in the accompanying circuit documents for both the analytical computer and the measuring element. The fol- lowing connection assignment applies. 20 PE 19 PE Figure 14: Connection terminal Manual PGC 9300 EN07 June, 18th 2018...
  • Page 54 50 m between the control cabinet and PGC. Clamping ranges of cable glands (permissible cable diameter): number Inner casing Outer casing Ex-PGC 3.1 – 8.6 mm 6.0 – 13.4 mm 6.1 – 11.6 mm 9.5 – 15.9 mm Manual PGC 9300 EN07 June, 18th 2018...

  • Page 55: Gas Connections

    (VDI 3490 page 3, Dec. 1980). Note It must be ensured prior to commissioning that the gases that are used correspond to the specified requirements. Manual PGC 9300 EN07 June, 18th 2018...

  • Page 56: Carrier Gas Connection

    The pressure at the analytical computer can be read on the “Status” screen and fine adjustments can be made when checking the display value. Connection values: 5.5 bar ( 10%) Manual PGC 9300 EN07 June, 18th 2018...

  • Page 57: Sample Gas / Calibration Gas / Reference Gas Connection

    (GC 9300 manual). 4.4 Further process The “Normal Calib.” operating mode must be selected after compensation of the input pressures according to the description above. The chromatograph will now conduct a calibration cycle. Manual PGC 9300 EN07 June, 18th 2018...
  • Page 58 4 Connection and commissioning If the first calibration is faulty, the PGC 9300 will start another calibration after a few minutes. If the second calibration is also faulty, the PGC 9300 automatically switches to the operating mode “Stop”. The PGC 9300 automatically switches to “Autorun” mode after successful calibra- tion.

  • Page 59: Interruption Of The Carrier Gas Supply

    (regular flushing of pressure regulators and supply lines!), the inlet pressure should be checked (inlet pressure regulating unit). After the inlet valve (Figure 6: Gas chromatograph PGC 9300 / A and D) has been opened, a further check can take place on the analytical computer (“Status”...
  • Page 60 4 Connection and commissioning Alternatively, the PGC 9300 can be prepared for a longer period of storage by flushing the device with nitrogen (5.0) at 3 bar for at least 15 minutes at all inlets. Then all inlet valves must be closed and then the two outflow lines must also be provided with a gas-tight seal with dummy plugs.

  • Page 61: Operating Modes Of The Device

    Then an automatic switch to “Autorun” occurs. After re-calibration, the external calibration gas is analyzed via the reference gas inlet. This is a normal analysis and the correction factors from the last automatic or manual calibration remain unchanged. Manual PGC 9300 EN07 June, 18th 2018...

  • Page 62: Basic Calibration

    A calibration cycle is triggered and the determined factors are stored in the com- puter as response factors of the basic calibration together with the retention times. After the calibration cycle, the system switches to “AUTORUN” mode. Manual PGC 9300 EN07 June, 18th 2018...

  • Page 63: Appendix 1: Technical Data

    The device must be protected against direct weather influences. PTB = Physikalisch Technische Bundesanstalt (Physical Technical Calibration and Test Federal Institute) Dimensions: see Figure 6: Gas chromatograph PGC 9300 Weight: 75 kg Manual PGC 9300 EN07 June, 18th 2018...
  • Page 64 DN Ø nominal diameter Sectional view weldolet thread inch weldolet height L2 pipe wall thickness engaged length L3 (Pos.3) connecting pipe Ø cover isolated screw connection Manual PGC 9300 EN07 June, 18th 2018...
  • Page 65 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. Manual PGC 9300 EN07 June, 18th 2018...
  • Page 66 Shut-off valves and fittings in 11.) Ex(e)(i) connection box for pos. 10 and Swagelok system (stainless steel) sample gas pipe heating 12.) holder for wall installation Total weight approx. 30 kg 13.) restrictor ø 0.4 mm Manual PGC 9300 EN07 June, 18th 2018...
  • Page 67 Shut-off valves and fittings in 12.) Ex(e)(i) connection box for pos. 11 and Swagelok system (stainless steel) sample gas pipe heating Total weight approx. 70 kg 13.) restrictor ø 0.4 mm 15.) insect safety-sieve Manual PGC 9300 EN07 June, 18th 2018...
  • Page 68 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) Manual PGC 9300 EN07 June, 18th 2018...
  • Page 69 Appendix 1: Technical data Pressure Reducing Unit Type DRS100 Manual PGC 9300 EN07 June, 18th 2018...
  • Page 70 = 0-8 bar inlet pressure = 100 bar 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 Manual PGC 9300 EN07 June, 18th 2018...
  • Page 71 DIN 477, No. 6 or BS 341, No. 3 9.) high pressure helix (stainless steel) with all pipes and pipe fittings in Swagelok cylinder connection acc. to DIN 477, No. 14 or BS 341, No. 4 system from stainless steel Manual PGC 9300 EN07 June, 18th 2018...

  • Page 72: Appendix 2: Error Messages

    Carrier gas pressure - The carrier gas inlet pressure is outside - Incorrect setting of the tolerance. - Cylinder pressure - Check “Status” screen Manual PGC 9300 EN07 June, 18th 2018...

  • Page 73: Appendix 2 B: Errors During Recalibration

    When this process is completed and the measuring element is ready, a calibration is initiated automatically (after a speci- fied wait time). The analysis operation resumes after the calibration. Manual PGC 9300 EN07 June, 18th 2018...

  • Page 74: Appendix 3: Pre-Filter Flushing Unit

    Therefore, a replacement can take place simply when exchanging the pre-filter unit types. Installation diagram The following Figure 15: Installation diagram shows the installation. Figure 15: Installation diagram Manual PGC 9300 EN07 June, 18th 2018...

  • Page 75: Manual Pgc 9300 En07 June, 18Th

    Vent valve for Filter A Inlet valve for Filter B Outlet valve for Filter B Vent valve for Filter B Adjustable variable area flow meter for He Blow-off line Connection to the blow-off line Manual PGC 9300 EN07 June, 18th 2018...
  • Page 76 Appendix 3: Pre-filter flushing unit Figure 17: Functional diagram Manual PGC 9300 EN07 June, 18th 2018...
  • Page 77 Open valve B1 Open valve B3 Adjust RM for flushing operation to 10-15 ml. Flush for 24 h Close valve B3 Close valve A2 Open valve B2 Close valve A1 Filter A can be removed Manual PGC 9300 EN07 June, 18th 2018...
  • Page 78 Switch He filter to Pos. A Open valve A1 Open valve A3 Adjust RM for flushing operation to 10-15 ml. Flush for 24 h Close valve A3 Close valve B2 Open valve A2 Close valve B1 Manual PGC 9300 EN07 June, 18th 2018...

  • Page 79: Appendix 4: Certificates

    Manual PGC 9300 EN07 June, 18th 2018...
  • Page 80 RMG Messtechnik GmbH Otto-Hahn-Straße 5 35510 Butzbach, Germany Phone: +49 (0) 6033 897 – 0 Fax: +49 (0) 6033 897 – 130 Email: service@rmg.com Manual PGC 9300 EN07 June, 18th 2018...

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