ABB 8206

Natural Gas Chromatograph

Gas Commissioning Team

Operations & Technology, Jebel Ali Dubai

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 Contents

1. PCCU7 Software
a. Making a Connection
i. Connecting via the USB Port
ii. Connecting via the Ethernet Network
b. Checking for Faults
c. Resetting Faults
d. Checking the Peak Find timings
e. Checking the Peak Labels
2. Maintenance
a. Daily Checks
b. Weekly Checks
c. Monthly Checks
d. Replacing Carrier Gas Bottle
e. Replacing the Calibration Gas Bottle
3. Data Collection
4. Contact Details
a. Aggreko Gas Commissioning Team Contact Details

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 Chapter 1a

Making a Connection to the Gas Chromatograph using the PCCU7 Software.

The ABB Gas Chromatograph uses its own software in order to allow the user to communicate with
the device. During the Commissioning of the Chromatograph the device will be configured to
configure via either USB, using the port installed on the device, or via an Ethernet Network.

Chapter 1.a.i - Connecting via the USB Port

To make the Connection your Laptop will need to be equipped with two Programs

1) PCCU
2) Windows Mobile Device Centre

Both Programs will be installed by the Commissioning Engineer during the initilal configuration of
the Gas Chromatograph.

Step 1.
Connect the Laptop via the USB Port. Windows Mobile Device Centre should automatically launch
and will display the message ‘Connected’. Failing to do this will result in no connection being
established.

Step 2.
Open the ‘PCCU’ Software. (The Commissioning Engineer should have configured all settings to auto-
load, but they are also described in Steps 3 through Step 4

Step 3.
Select ‘ActiveSync NGC’ in the ‘PCCU Connect Method Menu’

Step 4.
Select ‘Entry’ in the ‘Auto Connect Menu’

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 The Chromatograph is now configured to automatically take you to the screen shown below:

Chapter 1.a.ii) Connecting via the Ethernet Network

Before being able to connect the ‘IP Address’ and ‘Subnet’ must be configured within the
Chromatograph. You must make the initial connection via USB and then follow the below steps.

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Step 1.
Click on the ‘Show Tree View’ button

Step 2.
Click on the ‘Communications’ Tab

Step 3
Click on the ‘Network Tab’

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Step 4.
Configure the Network Settings to suit the location

Note: That if the Site is to be SCADA Configured these settings will need to match the SCADA System.
Each Time you make a change (line by line). Click ‘Send’

Step 5.
After the IP Address and Subnet Settings have been configured the device must be ‘Power Cycled’ to
make them Permanent. Simply remove the AC Supply and wait 10 seconds before restoring the
Power.

Step 6.
Connect the Laptop via the Ethernet Port.

Step 7.
Configure the Laptop so that it is on the same ‘Subnet’, but with a different ‘IP Address’ again this
should be in line with the SCADA configuration (if used).

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Step 8.
Open the ‘PCCU’ Software, then, Open the ‘Setup’ Menu.
Windows Mobile Device Centre is not required when communicating via Ethernet

Step 9.
Select ‘TCP/IP’ in the ‘PCCU Connect Method Menu’, then, Select ‘Entry’ in the ‘Auto Connect Menu’

The Chromatograph is now configured to automatically take you to the screen shown below:

Chapter 1b - Checking for Faults

After making the Connection as described above, the Software will automatically direct you to the
screen shown below:

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 Any Faults will be shown on the affected stream.

System Alarms can be checked by clicking the large green circular indicator shown above

Individual Stream Alarms can be checked by clicking the box at the top of each stream

Historical Alarms can be checked by clicking ‘Alarm Logs’

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 Chapter 1c – Resetting Faults

First click ‘Alarm Logs’

Select the ‘Alarms not Acknowledged’ Tab

Investigate the Faults listed. Once you believe they are rectified click ‘Ack All’

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 Return the Chromatograph to Service by clicking the ‘Run’ button

Note: Any Faults that were recognised may still be shown on the Stream until at least one full Cycle
has been competed, and the unit recognises the unit is without issue.

Chapter 1d – Checking the Peak Find Timings

From the ‘Entry’ Screen, select the Chromatogram for the relevant Stream

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 This will open the Screen shown below:

Zoom in on the final Peak, and check the time at it eludes at 160s +/- 3 seconds, for C3-C6+

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 Repeat the Process for the N2-C2 Chromatogram

Zoom in on the final Peak, and check the time at it eludes 220s +/- 3 seconds, for N2-C2

Any irregularities should be noted and reported to the Gas Commissioning Team at the earliest
Opportunity.

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 Chapter 1e – Checking the Peak Labels

All Peaks should be labelled, and have clearly identifiable ‘Gates’ (Green Gate On, Red Gate Off)

Any irregularities should be noted and reported to the Gas Commissioning Team at the earliest
Opportunity.

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 Chapter 2 – Maintenance

a) Daily Checks:

Check for Faults using PCCU Software

b) Weekly Checks:

Check Cylinder Pressures

Helium Cylinder Pressure (New): 200 BarG

Helium Cylinder Pressure (Change): 10 BarG
Calibration Gas Pressure (New): 70 BarG
Calibration Gas Pressure (Change): 1 BarG (or before expiry date)

Please keep in mind lead times when ordering your replacement Cylinders

Check Regulator Pressures (Outlet).

Carrier Gas Pressure (Helium): 6.2 BarG (90 PSI)

Calibration Gas Pressure: 1 BarG (15 PSI)

Stream Sample Pressure: 1 BarG (15 PSI)

c) Monthly Checks:

Perform Leak Test using Snoop Leak Detection Fluid

d) 6 Month Check:

Replace the Filters of the Sample Conditioning Module, after the first two Changes the frequency can
be adjusted to Annual if the Filters are Clean when Changing. If they are dirty the frequency should
be adjusted to 3 Month interval

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 e) Replacing the Carrier Gas Cylinder

Do not replace either Cylinder when it is raining

Step 1.
Connect a laptop to the NGC and place the analyzer in HOLD

Step 2.
Close the bottle

Step 3.
Carefully take off the 1/4” Swagelok connection and let the remaining pressure escape

Step 4.
Loosen the bottle connection to take off the regulator

Step 5.
Connect the regulator to the new bottle

Step 6.
Turn the pressure set knob fully counter clockwise to set the output pressure to 0

Step 7.
Open the new bottle and close it again

Step 8.
Allow Helium to escape from the regulator by turning the pressure set knob clockwise. If
all the pressure has been released, turn back the knob fully counter clock wise

Step 9.
Repeat step 7 & 8 three times

Step 10.
Finally re-connect the 1/8” Swagelok connection

Step 11.
Open the bottle and set the output pressure to 90 [psig]

Step 12.
Check for leaks using Snoop

Step 13.
Let the analyzer pass the diagnostic start-up test

Step 14.
Put the analyzer in RUN

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 f) Replacing the Calibration Gas Cylinder

The lifetime of a calibration gas, when free of leaks, is usually restricted to its
certified end date. The NGC uses so little gas, that if the cylinder runs empty, it
usually indicates a leak.

Step 1.
Connect a laptop to the NGC and place the analyzer in HOLD

Step 2.
Close the calibration gas cylinder

Step 3.
Carefully take off the 1/4” Swagelok connection and let the remaining pressure escape
Remove the regulator from the bottle

Step 4.
Connect the new bottle

Step 5.
Remove the 1/16” connection from the NGC feed thru

Step 6.
Open the bottle and close it again to allow the pressure to drop to zero, so that the
regulator and tubing are flushed with the new gas

Step 7.
Repeat step 5 four (4) times

Step 8.
Re-connect the 1/16” connection to the NGC feed thru

Step 9.
Open the bottle and verify the correct output pressure of 15 [psig]

Step 10.
Check for leaks (preferably using Swagelok Snoop leak detector)

Step 11.
Connect a laptop to the NGC either using USB or Ethernet

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Step 12.
Use the calibration certificate to enter the new component concentrations into the
analyzer by clicking on ‘Calibration’

Step 13.
Enter the new concentration of each component in the list. The total should be 100%.
Should the totals not equal 100%, adjust the Methane (C1) accordingly.

Step 14.
Click on SEND

Chapter 3 – Data Collection

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The ABB Gas Chromatograph uses an SD Memory Card to record all Data from Streams Sampled. In
the event of a Power Loss the Data will not be lost, and can be retrieved at any point by following
the below procedure.

Step 1.
Make the Connection to the Gas Chromatograph by either USB or Ethernet Connection.

Step 2.
Click on the ‘Collect’ Tab

Step 3.
Select All Data to be Collected (this will depend on the amount of Streams in use)

Step 4.
Click ‘Collect’

You will now be presented with the Data Collect in a Tabular Form, as shown below:

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Should you wish to use the Data in an Excel Format you must follow the following route

Navigate to ‘Windows Explorer’

Navigate to ‘Local Disk (C:)’, Double Click

Navigate to ‘PCCU7’, Double Click

Navigate to ‘spreadsh’, Double Click

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Navigate to ‘archive’

Navigate to the Correct Device Serial Number, Double Click

From this location you may access any of the three Excel Sheets

These Files will be updated each time the Data is collected from the Gas Chromatograph.

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Contact Details - Aggreko

Aggreko Gas Commissioning Team

Name Email Telephone Number
Brendan McClelland [email protected] +971 (0) 5653 86874
Deon Coetzee [email protected] +971 (0) 5021 31780
John Pearson [email protected] +971 (0) 5055 96066
Paul Van De Graaf [email protected] +971 (0) 5668
66031

Contact Details – ABB Dubai

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