HS RGA Operating Manual PDF
HS RGA Operating Manual PDF
GAS analyzer
Operating manual
Manual part number 23070.088 version 2.2
Notices
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respective owners.
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Operating Manual
Edition: September, 2013
Version: 2.2
1 Introduction
1.1 Who should read this guide
This guide is intended for people installing the AC Hi-Speed Refinery GAS analyzer and
accompanying software, or any part of it.
Chapter 2: Before you begin the installation provides a check list to make sure everything is
present for a successful installation.
Chapter 3: Installing HI-speed Refinery Gas analyzer describes how to install the hardware
parts of the analyzer.
Chapter 4: Installing the Chromatographic Data System describes how to install and
configure your CDS.
Chapter 5: Installing GASXLNC™ Software describes how to install and configure the GasXLNC
software.
When you receive the instrument from AC Analytical Controls, it has been factory tested. If
you have also received a PC with the system, it has been used to perform the factory test.
This means that all software is already installed on the PC. However some configuration still
needs to be done.
Site requirements
Required gasses available (See 2.1 Gas requirements)
Sufficient bench space available
More information can be found in the AC site preparation and installation requirements prior to the
installation.
Unpacking
Unpack and verify condition and completeness of the shipment
Packaging complete (packing list)
System Configuration
Agilent 7890 series Gas Chromatograph
S/SL inlet
Thermal Conductivity Detector(s)
Flame Ionization Detector
AC hardware modification
PC requirements
Processor 2.8 GHz or higher
60 GB or more free hard disk space
(CD) DVD ROM device
Mouse or other pointing device
Access to a printer (e.g. local connected using USB or accessible via corporate
network)
LAN: 10/100baseT
Monitor with resolution 1024 x 768 or higher (recommended at least 1280 x 1024)
Windows 7 Service Pack 1 or higher, Windows XP Service
1
Pack 3 or higher, or
Windows 2003 Server Service Pack 2 or higher installed – US English versions only
Agilent G2070BA Chemstation32bit software2 for 1 GC or Agilent G2071BA
Chemstation32bit software for additional GC
AC GAS
XLNC™
software
Only very low ppm levels (0.5 ppm) of oxygen and total hydrocarbons should be present in
the gas supplies. Oil-pumped air supplies are not recommended because they may contain
large amounts of hydrocarbons. The addition of high-quality moisture, hydrocarbon, and
oxygen traps immediately after the main tank pressure is highly recommended. Refer to the
section "Gas Supply" of the Agilent GC Site Preparation Checklist for more information on
using traps.
It is possible to use a compressor for the air supply. The air must be free of water and oil for
the FID. The compressor must be capable to supply sufficient air to maintain a 3 bar
pressure.
The FID is very sensitive to hydrocarbons. If hydrocarbons are present in any of the gasses
in quantities greater than the trace amounts, baseline noise will result. Charcoal filters will
filter out hydrocarbon impurities.
Switching Air > 45 PSIG (3 Bar)
The helium and hydrogen gas lines must be made of stainless steel or copper.
The gas fittings are located at the rear of the gas chromatograph. All of the gas connections
are 1/8 inch male Swagelok fittings. The helium, hydrogen and nitrogen lines are connected
directly to the GC.
For North America and geographical areas that use 110 - 120 VAC :
Gas chromatograph: 120 VAC. Please refer to the Agilent Site Preparation Checklist for
additional information if required.
All accessories: 110 - 120 VAC, 4 standard 3 prong grounded outlets.
Gas chromatograph: 220/230/240 VAC, Please refer to the Agilent Site Preparation
Checklist for additional information if required.
All accessories: 220 - 240 VAC, 4 grounded outlets
Maximum power consumption of the 7890 gas chromatograph is 2,250 VA for a regular oven
and 2,950 for a fast-heating oven.
Do not turn on the oven until all electrical and gas connections have been
completed and checked for correctness and leaks.
3.1 Prepare
Please make sure you are ready to begin the installation. See chapter 2: Before you begin
the installation for details.
Make sure that all power inlets are configured for the supplied voltage.
3.2 Install
The AC Hi-Speed Refinery GAS analyzer system consists of a number of basic hardware
parts and dedicated software for operation and data handling.
The Gas Chromatograph will vent hot (185 °C) oven air from the rear of the
Gas Chromatograph when the oven is cooling down to ambient temperature.
Ensure that nothing is placed behind the gas chromatograph that should not
come in contact with the hot exhaust air. Agilent manufactures an "Oven
Exhaust Deflector” (AC part no. 59.40.200) that deflects the exhaust air away
from the rear of the gas chromatograph. This device is easily and quickly
attached to the rear of the gas chromatograph. Please contact your local AC
office to order / install this device.
Do not switch the oven on before all electrical and gas connections have
been completed and checked for leaks.
Air
FID Air FID H2 Front Inlet Actuator
Control
Aux 3
Aux 1
Aux 2
Regulator
He He N2 N2
Nitrogen
Helium
He Vent
TCD Vent
Instrument Air
LAN
Power
All gases are dangerous when compressed. Do not store gas cylinders where
they might be dropped or exposed to excess heat. Always direct the flow of
compressed gases away from people.
The electrical power to the complete system should still be turned off.
The FID air supply should be zero grade to prevent excessive baseline noise.
The helium and hydrogen gas lines must be made out of stainless steel or
copper tubing. Teflon tubing must not be used for these gases. When using
Teflon tubing for the air connections, make sure not to over-tighten the
connection. The tubing may be squeezed too tight causing a restriction for
the air.
Make sure a printer is installed. This can be either a local or a network printer.
Printer Computer
7890
Mouse
1 - LAN interface PC - GC
Figure 3-2 Cabling configuration for the Agilent 7890 Series GC.
3.3 Startup
After the gas and electrical connections are made, you can switch on the 7890 GC.
Particularly when the instrument is just installed, it is important to flush the system with
carrier gas for some time to remove most of the air out of the instrument. Do not heat up a
thermal zone when flushing the system during startup. Then it may still take several runs
before the system is free of air and it may take several days before the system is free of
moisture.
The following instructions assume that you use the GC key panel to set temperatures and
flows.
3.3.1 Procedure
See for the actual flows, pressures and temperatures chapter 4: Actual
settings of the analyzer in the supplied factory test documentation with the
analyzer.
3.4 Validate
The next checks can be executed to validate Hi-Speed Refinery GAS analyzer installation.
In the Hi-Speed are two Needle valves located which have to be tuned with the startup of the
instrument or after column 6 conditioning (13X column) or column 6 replacement.(See
chapter 6.1)
Both Needle valves are located inside the left side. (See chapter 6.1 figure 6-
2 and 6-4). Needle valve 1 is located at the back of the front plate of the left
side.
TCD Vent and Helium (He) Vent are located at the rear of the leftside.
When both the instrument and the computer are bought together from AC Analytical
Controls, the requested Chromatographic Data System is already installed and configured on
the computer. It might still be necessary to adjust the configuration to support the new
environment.
4.1 Prepare
Make sure you have all the necessary information (e.g. IP addresses) available to begin
installation of the Chromatographic Data System. If different type of installations are
supported (e.g. Client/Server) select the installation type suited for your needs.
When the CDS is installed, configure an instrument for the GC. The type of GC can be found
on the label attached to the GC (e.g. 7890). More information can be found in the Agilent GC
manuals and the manuals of the CDS.
Examples:
Chemstation B.04.03 (Configuration Editor) OpenLab C.01.03 Chemstation (CP)
4.3 Validate
After connecting to the instrument, the CDS software shows status information of the
Hi-Speed analyzer.
.
If both the instrument and the computer are bought from AC Analytical Controls, GasXLNC™
software is already installed and configured on the computer.
5.1 Prepare
The GasXLNC™ software co-operates with the Chromatographic Data System. Make sure the
Chromatographic software has been installed and configured correctly (See chapter 4).
5.2 Install
PC User requires full acces rights for the XML installation and configuration.
Insert the GasXLNC™ Installation CD. This may bring up an ‘AutoPlay’ dialog; if so select the
‘Run CD_Start.exe’ option. The installation software will be started. If not, browse to the CD
and start the CD_Start.exe application. The following dialog is shown:
Click the “Install Gas XLNC” button to start the installation of the GasXLNC™ software. If a User
Account Control message dialog pops up, click Yes to continue installation. A wizard will be
started which guide you through the installation process. Clicking ‘Next >’ will advance to the
next step in the wizard. Clicking ‘< Back’ will move back to the previous step. ‘Cancel’ can be
clicked to abort the wizard and the software will not be installed. Installing the software using
the default options will suit most users.
Below some steps of the wizard (screens) are explained. Please note that some screens will
not appear or may look a little different, depending on your choices and your situation.
Copy the methods from the CD to the respective method folder in the GasXLNC program
folder (e.g. 7890 GC, default installation: C:\Program Files\AC Analytical
Controls\GASXLNC\Applications\Hi-Speed RGA\Chemstation\Methods\7890). Run the
Configurator, make sure “copy methods” is checked and click Modify.
6 Operation
This section describes the operation, configuration, and analysis of Analytical Controls (AC)
Hi-Speed Refinery Gas Analyzer. The AC Hi-Speed RGA is based upon the Agilent 7890A
Series gas chromatograph (GC). For more information, refer to the appropriate Agilent
manuals for detailed information on the Agilent 7890 GC.
The AC Hi-Speed RGA consists of an Agilent 7890A Series GC optimized for refinery gas
analysis, Agilent Chemstation for instrument control and GasXLNC™ for data handling. The AC
Hi-Speed RGA determines hydrocarbons from C1 up to C6+, carbon dioxide, carbon
monoxide, nitrogen, oxygen, helium, hydrogen and hydrogen sulfide.
6.1 Configuration
The AC Hi-Speed RGA application for determining the composition of refinery gases uses an
Agilent 7890A Series GC with electronic pneumatics control (EPC) configured with four micro
packed GC columns, two capillary columns, three six port rotary valves, two ten port rotary
valves, a split/splitless inlet, a sample shutoff valve, a flame ionization detector (FID) and two
Thermal conductivity detectors (TCD). The micro packed columns are mounted in an
isothermal column oven located in the left-hand side of the chromatograph. The capillary
columns are mounted in the GC oven, four rotary valves are mounted in an isothermal valve
oven also located in the left side of the chromatograph, while the fore flush/back flush valve
of the hydrocarbon channel is located on the back inlet position. The sample shutoff valve is
mounted separately in the left side.
Figure 6-1 to Figure 6-5 illustrate the flow diagram, the left side, the front side, the column
positions of the AC Hi-Speed RGA.
Column 2 Column 1 V1
Front Inlet Aux 3 NO
Gas
N2 Sample in
He 25ul 50ul
1
V2 1
V6 V3 1
2 10
2 6 2 6
3 9
Column 5
3 5 3 5 4 8
5 7
4 4 6
S/SL
N2
FID TCD
Front Back
Air H2 TCD
Aux
Gas V4 50ul V5
Sample out Column 3 NV- Column 6 He
2 1
10
Bypass 1
3 9 Col 6 2 6
Aux 1 N.V Vent He
4 8 3 5
He 5 7 4
6
Aux 2
He Column 4
RIGHTSIDE GC
DETAIL LSV
SCALE 1:1
SEE DETAIL BF
SCALE 1:1
DETAIL BF
SCALE 1:1
Operation
TCD Vent
Aux 1
Front Inlet
Gas Sample In
detail R detail P
connection connection
Gas connections
gasses Sample
sample line connections
SOLENOID
PRESSURE REGULATOR
VALVE 5
VALVE 4
VALVE 3
VALVE 2 DIN RAIL ADAPTOR
VALVE 1 ONLY USED FOR REPLACEMENT SETUP
Column 2
V6
1
2 6
3 5 Front Inlet
4 Split/splitless
Column 1
Pre column
FID
Figure 6-7 The AC Hi-Speed RGA capillary column positions in the GC oven.
Over the past different configurations have been used regarding the use of
needle valves in the system configuration. See the factory test documentation
applied with the analyzer for the used system configuration. See chapter 3.5
for needle valve adjustments if columns are conditioned or replaced.
Valve 1 is configured as a switching valve in the Chemstation method and the on/off settings
are in the Chemstation runtable. This allows the user to start the analysis from GasXLNC™
sequence editor. In the Chemstation method the injection source is manual. This means that
the analysis is always started by pressing the start button on the GC.
The length of the columns is nominal. The columns are conditioned and tuned at the factory to give the required separation and
timing.
All columns should be conditioned in the system at 110°C except for column 6.
* Column 6 should be conditioned at 350°C. Therefore the column must be removed and
conditioned in a separate GC.
Standby
S/SL
Front Inlet (He) Column 1 Column 2 FID
S/SL
Front Inlet Column 2 Column 1 FID
Standby
Standby
Aux 1 (He) Column 4 Column 6 TCD
Aux 2 Vent He
Stopflow Column 6, backflush Column 3, elution Column 4 (Valve 5 On, Valve 4 Off)
The sample is introduced into the system using a sample loop that can be switched into the
flow using Valve 2. The contents of the sample loop is then transferred to the split/splitless
inlet. Here it is mixed with carrier gas and a small portion is transferred to the pre column. On
this column a pre separation takes place. Just before the elution of n-Hexane from this
column to the aluminum oxide Plot column, Valve 6 is switched. Now the flow on the pre
column is reversed and simultaneously the pre column is placed behind the aluminum oxide
Plot column. N-Hexane (and any heavier components) are now back flushed from the pre
column to the detector, followed by the hydrocarbon compounds on the aluminum oxide
column that are separated in a temperature programmed oven run.
After the sample has been introduced into the system by switching Valve 3 ON, Helium and
Hydrogen are separated on the HayeSep/Molsieve column. After the elution of Hydrogen, the
heavier components are back flushed to the detector. This is done by switching Valve 3 Off.
After the sample is introduced into the system by switching valve 4 ON. Oxygen, Nitrogen,
Methane and Carbon monoxide quickly pass both HayeSep columns (columns 3 and 4) and
elute onto the Molsieve column (column 6). Here these components are trapped by switching
Valve 5 On.
Then carbon dioxide, C2 Hydrocarbons and Hydrogen Sulfide elutes from the HayeSep Q
column (column 3) to the HayeSep N column (column 4.) Just after the elution of Hydrogen
Sulfide from the Haysep N column, Valve 4 is switched OFF, back flushing all remaining
components from the HayeSep Q column to vent. In the meantime Carbon dioxide and
Hydrogen Sulfide are separated on the HayeSep N column and detected by TCD 3C.
After the elution of Carbon dioxide from the HayeSep N, the Molsieve column is put in flow
again and the permanent gases are separated and detected by TCD 3C.
6.4 Operation
The AC Hi-Speed analyzer uses the Gasxlnc fully integrated with the data system in a
Microsoft Windows environment to control all GC functions. This integrated software package
automates all aspects of the calibration, calculation and customized reporting.
The Agilent Chemstation method: RGA_HIX.m takes care of instrument controlIt is used for
all Gas sample analysis (GSV). LPG.m is used for Liquid Samples (LSV), Front channel only.
GasXLNC is used for Data handling and calibration. Integration is done by the Chemstation
method.
For detailed information how to operate the GasXLNC software, refer to the
GasXLNC operator manual
The tuned Database is applied with the system on the methods and data CD.
To use the database provided on the CD, copy the “database”-file to the
folder C:\Temp (create if it doesn’t exist). Start the GasXLNC™ software.
Restore the database from the File menu. Browse to the “c:\temp” folder,
select the “bak”-file and click OK. Close the software when done.
6.5 Calibration
Use GasXLNC for the calibration of your components. Refer to the operating manual of
GasXLNC for more information regarding calibration.
Set the sequence event for the first calibration analysis to “Start new
calibration”.
3 Perform more calibration runs if you wish to average the response factors.
4 Use the calibration browser to view the calibration points in a plot and to discard
analyses that are faulty.
5 Recalibrate the calibration set if analyses are removed or updated.
6.5.2 Reports
There are standard report options in the GasXLNC software to present the sample or
calibration results like: Overall Report 7890 (with signal plots) or Small Report (components
results only) For Sample analysis special calculations are added to the reports.
In that case, the liquid sampling valve is located in the left-hand side compartment of the
chromatograph and is controlled by valve 7.
He
Column 2 Column 1
Front Inlet
Liquid 25ul
Sample in
1
V2 1
V6
S P 2 6 2 6
w C
3 5 3 5
0.06ul 4 4
V7 S/SL
Liquid
Check loop
FID
Liquid
Front
Sample out Air H2
Figure 6-9 Detail of Hi-Speed Refinery Gas Analyzer with Liquid Sampling Valve
flow diagram
The LPG sample is injected through the liquid sampling valve, enters the split/splitless inlet
Here it is mixed with carrier gas and a small portion is transferred to the pre column. On this
column a pre separation takes place. Just before the elution of n-Hexane from this column to
the aluminum oxide Plot column, Valve 6 is switched. Now the flow on the pre column is
reversed and simultaneously the pre column is placed behind the aluminum oxide Plot
column. N-Hexane (and any heavier components) are now back flushed from the pre column
to the detector, followed by the hydrocarbon compounds on the aluminum oxide column that
are separated in a temperature programmed oven run.
6.6.1 Calibration
LPG Analysis uses relative response factors, therefore no calibration is needed.
6.6.2 Operation
The next procedure describes the step-by-step sample introduction done by a liquid sampling
valve.
1. Verify the pressure of the sample cylinder. The pressure should be lower than the rating
of the BPR (< 375 psi / 25,8 bar).
If the pressure inside the sample cylinder is higher than the rating of the BPR,
you will not be able to supply enough back pressure. The result will be that the
BPR stays “open”, resulting in continuous flow of sample until the pressure inside
the sample cylinder is equal to the set pressure of the BPR.
Always connect the outlet of the sample line to a Fume hood, because the
samples are likely to be flammable and cause an explosion hazard when
mixed with air.
3. Connect the liquid sample cylinder to the “Liquid Sample in” connection at the left side of
the GC.
4. Increase the back pressure of the BPR almost completely by turning the handle
clockwise.
Check if there is no fluid or gas coming out of the GC sample outlet tubing. If
there is gas/liquid coming out, the sample pressure is higher than the BPR
range. See step 1.
8. Flush the sample tubing and sample loop until liquid fluid comes out of the sample out.
Do this, by slowly decreasing the back pressure of the BPR (turning the handle counter
clockwise). If the applied back pressure drops below the sample pressure, the BPR will
“open”.
9. After the samples lines have been flushed with a couple of mL sample, increase the back
pressure of the BPR again (by turning the handle clockwise), until (almost) no sample
comes out.
10. When the GC is ready for analysis: Press the START button on the GC to start the
analysis.
12. After the injection, decrease the back pressure of the BPR almost completely by turning
the green handle counter clockwise to flush the remaining sample out of the sample line.
After decreasing the back pressure completely, always turn the green handle
a half turn back (clockwise) to prevent the stem of the BPR getting stuck.
Check if the liquid check loop is empty and no gas is coming out of the GC
sample outlet tubing, before disconnecting any connection line.
6.6.3 Report
There is one standard report in the GasXLNC software to present the sample results: LPG
Report. For Sample analysis special calculations are added to the reports.
These settings are typical settings. Always check your test documentation for
the most up to date analyzer settings.
RGA_HIX.m is tuned for the analysis of Hydrogen Sulfide. If no Hydrogen Sulfide is present
in the sample the cuttimes of valve 4 Backflush column 3 can be set just after the elution of
Carbon dioxide and valve 5 switching can be changed
6.7.1 RGA_HIX.m
Component Description
Front
AC 21073.048Hi Speed
200 °C: 35 m x 320 μm x 8 μm
Columns In Front Inlet
Out Front Detector
Flow ~ 5 ml/min
Pressure ~ 187 kpa
Temperature 80 °C
Equilibration time 0.5 min
°C/min Next °C Hold min
Oven Oven ramp 80 2
35 185 ~2.5
Total run time 7.5
Post Run 50 °C
Post Run Time 0 min
RGA_HIX.m is tuned for the analysis of Hydrogen Sulfide. If no Hydrogen Sulfide is present
in the sample the method can be adjusted to a shorter runtime (~5min) by adjusting the oven
program and some Runtime events.
Component Description
Temperature 80 °C
Equilibration time 0.5 min
°C/min Next °C Hold min
Oven Oven ramp 80 2
35 185 ~0
Total run time 5
Post Run 50 °C
Post Run Time 0 min
Time (min)* Event Position Setpoint Description
Run Time
0.3 Valve 4 Off Back flush column 3
Events
2.5 Valve 5 Off Elution column 6
4.99 Valve 6 Off End backflush FID channel
*Typical settings. Cut times has to be experimental determined
Component Description
Temperature 80 °C
Equilibration time 0.5 min
°C/min Next °C Hold min
Oven Oven ramp 80 2
35 185 ~0
Total run time 5
Post Run 50 °C
Post Run Time 0 min
Time (min)* Event Position Setpoint Description
Run Time 0.01 Valve 7 On Injection on FID channel
Events 0.3 Valve 6 On Back flush FID channel
1.0 Valve 7 OffEnd injection FID channel
4.99 Valve 6 OffEnd backflush FID channel
* Times will be fine-tuned and included with checkout documentation for each gas analyzer.
PAC Authorized Representatives are also located in most countries worldwide. More
information can be found on www.paclp.com.
In any verbal or written correspondence with AC concerning your analyzer, you may be
asked to provide the following information:
Chromatographic Software
Version
Chemstation (OpenLAB)
License
Chromatographic Hardware
Agilent 7890 GC Serial Number
Sampler S/N
Computer
Serial Number (if provided by PAC)
Operating System
Windows XP Service Pack: Professional 32-bit English
Windows 7 Ultimate 64-bit
Windows 2003 Enterprise