process gas chromatograph transmitter · the gcx is the world’s first process gas chromatograph...

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• The first multi-application, multi-configuration process gas chromatographin a field mount transmitter package

• Supports thermal conductivity (TCD) orflame ionization (FID) detectors andanalysis of gaseous or liquid phasesamples.

• Approved for use in Class I, Zone 1 Gr.IIB+H2 environments

• Modular electronics and EZSlide OvenTM

assembly minimize maintenance andmean-time-to-repair (MTTR)

• Compact size and slim horizontal profiledramatically reduces installation spacerequirements

• Operates in stand-alone mode or as apart of a process GC network

• Advanced electronic pressure controlreduces maintenance requirements andcycle times

• Integral Quick-View LED display panelprovides instant status information oninstrument operation

• Intuitive and sophisticated Microsoft®

Windows®* based man-machine-interface(MMI) program simplifies chromatographcommissioning, operation, andtroubleshooting

• Field-mountable enclosure minimizes theneed for an environmentally controlledshelter or continuous air feed

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The GCX is the world’s first process gas chromatographconfigured as a field mount transmitter which has beenspecifically designed for advanced multi-component, multi-stream chromatographic analysis over a wide range ofindustrial applications. Unlike conventional GC “transmit-ters” which are suitable for only niche applications, the GCXintroduces the benefits of smaller size, reduced utilityrequirements, field mounting, and completely modularconstruction for a broad range of process applications.

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The instrument is housed in an explosion proof, dualcompartment enclosure suitable for hazardous areainstallation. A volume-limiting barrier effectively providesseparation between the electronics section of theinstrument and the chromatographic analysis section. TheGCX enclosure has been engineered to allow fieldmounting without additional ambient controls or shelters inall but the harshest environmental conditions.

In most of these installations a three-sided shelter providingminimal protection from direct sun, rain, or snow isgenerally adequate. In rare instances where additionalprotection is required the GCX packaging is still a valuableasset since shelters can be smaller in size and need bedesigned only to prevent ambient temperature extremes.

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Product Data SheetPDS 103-888.A01

May, 1999GCX™

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Screw type terminal blocks housed in an increased-safety-box (ISB) mounted above the GCX electronics enclosureprovide the interface for termination of power andcommunications conductors. When the GCX is installed ina hazardous area, power and signal wiring may beterminated at the ISB via armored cable (Europeanconvention) or, by increasing knockout size, rigid conduit(U.S. standard).

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The GCX includes a universal power supply (90 to 264VAC) or may be optionally powered by a direct 24 VDCsupply. Signal interconnection consists of the primaryRS485 multi-drop network that will support from 1 to 36instruments. Also included is an RS 232 interface for localMMI support, a local chromatogram output, 6 digital inputsand 6 digital outputs for various control, indication, andalarm functions, and an RS422 Modbus interface forinterconnection with a host computer or DCS.

The instrument also features an integral operator interface/display panel. LED status lights indicate the operationalstatus of the instrument including: cycle status, streambeing sampled, detector status, oven status, VLSIV or SHStemperature zone status, valve status, and normal-warning-failure common alarm status.

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For single stream applications the GCX is designed forinstallation without the need for additional sample handlingequipment. A clean, dry, particulate free, pressureregulated sample is all that is required. Provision forintroduction of calibration standards, carrier gases, and/orFID fuel and air support gases are provided throughconventional Swagelok™ type fittings. Where additionalsample stream capability is required the instrument may beprovided with an integral explosion proof sample handlingsystem module capable of supporting heated samples andup to four streams. If instrument air is available or shouldeven greater stream capability be required, the instrumentmay be fitted with a binary encoder for stream selectionallowing use of pneumatically driven sample system valvesfor up to 15 process streams plus calibration.

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O-Ring

Cover, ElectronicsCompartment

Electronic Assembly

Increased SafetyJunction Box

Oven Plate Assembly

PCB/Manifold Assembly

Oven Assembly

O-Ring

Cover, OvenCompartment

FEATURESThe GCX provides the advanced chromatographic andanalytical features of a world class instrument. Innovativenew features allow the “transmitter configuration” and the“gas chromatographic” methodology to be married for thefirst time.

Integral ControllerAt the heart of the GC transmitter is a powerfulmicroprocessor based system controller that providesanalysis of up to 20 components and/or pseudo-components for each stream. This analysis may besupported by up to 2 calibration methods and automaticstream sequence programming of up to 36 steps.Automatic peak detection, base-line correction, and slopedetect sensitivity levels may also be individually set for eachcomponent and method. Automatic storage of the lastmeasured chromatogram for each stream and calibration isautomatically provided.

The GC controller also provides non-volitile storage for allsystem operating parameters and operator selectablefunctions so, that should power be interrupted, no data islost.

Automatic calibration options include; Auto-calibration withoperator verification prior to accept, auto-calibration withauto update, or auto-calibration over an operator specifiednumber of cycles with averaged results auto updated.

Configuration OptionsA variety of hardware options dramatically increase thenumber and types of applications that may be served bythe GCX. Available instrument options include; single ordual carrier thermal conductivity (TCD) detectors, flameionization (FID) detector, single or dual conical rotary orpiston plunger type 10 port valves, vaporizing liquid sampleinject valve (VLSIV), and an optional FID detector withmethanator.

Modular ConstructionThe modular construction of the GCX offers maximumuptime and minimum MTTR (mean-time-to-repair) bysimplifying service to routine pull and replacement. In theelectronics section the GCX printed circuit boardassemblies are “euro-card” slide rail mounted and may beremoved and/or replaced without the use of tools.Sophisticated diagnostics allow, in most cases, servicepersonnel to identify the problem component beforearriving on site, ensuring that most electronics problemsrequire only a single visit. The modular component concepthas been further implemented in the unique design of theGCX oven. In this assembly all chromatographiccomponents including: columns, detector, valves, actuators,heaters, temperature sensors, and electronic pressure/flowcontrol components can be removed and replaced as asingle unit. The chromatograph oven as a replacement partis central to the GCX transmitter concept and maintenancephilosophy. Complete replacement of the oven assemblyas opposed to field repair of individual oven assembly asopposed to field repair of individual oven components

provides many advantages. First, repair personnel neednot wait for an oven cool-down period to begin repairs. Theoven can be removed as soon as the instrument has been

powered down. In fact, oven removal, replacement ovenre-installation, and instrument re-start can be completed inabout 60 minutes. Secondly, all replacement ovens arepre-calibrated for your specific application. Calibration andinstrument re-start can be completed on the first attemptwithout operator intervention or adjustment, maximizinginstrument availability. Also, repairs to the primary ovenassembly can be completed at your pace in your facility orours. No more worries about having the correct valve seat,column, heater, or fuse in stock. The correct replacementparts are always available because a spare oven is a sparechromatograph.

Electronic Pressure ControlThe GCX augments the traditional chromatographiccomponents used in the oven/analysis section of the devicewith state-of-the-art, patented, fluidic transistors or fluistors.These assemblies are actually miniaturized pressure/flowcontrollers that provide a number of advantages overconventional pressure regulators. Fluistors not only offer alow cost alternative, they allow precise control of criticalparameters in approximately twenty percent of the spacerequired by conventional methods. Electronic pressurecontrol is also used in the GCX to minimize routinemaintenance by eliminating routine adjustments. Typically,changes in GC base-line response are due to changes incritical flow paths or column performance and must becompensated for with needle valve adjustments. With theGCX, micro-pressure controllers eliminate these routineadjustments. The needle valves used to establish baselineresponse need only be adjusted if, and when, columnreplacement is required. Unlike instruments that utilizemicro-valves or other less-than-robust components forpotentially corrosive, particulate laden sample gases, theGCX fluistor assemblies control only ultra- pure carrier and/or detector support gases. Dependent upon applicationand instrument configuration the fluistor assemblies canalso be used to modulate the column head pressurereducing elution time and improving overall analysis cycletime.

Modular Oven Assembly can be replaced as a unit.

Data view screens provide operators access to time anddate stamped logs of the selected instrument’s opera-tion. All GCX MMI data can be saved in MicrosoftAccess™ compatible files should additional averaging,sorting, graphing or charting of data be desired. In theirnative format, the data log provides an indexed listing ofthe GCX network address, tag number identifying thedata source, the date of the analysis, the time of theanalysis, the stream sampled, and the calculatedconcentrations for each measured component. Forsafety, the operator is asked to select a default file sizeof 250 kb, 1mb, 2 mb, or 10 mb prior to enabling datalogging functions. This prevents accidental overfill ofhard drive storage space and potential system crashes.

#�$%�"��"��&��'""�(��Designed to operate in the Microsoft Windows* environment on a Pentium or higher personal computer, the GCX MMIsoftware is a highly sophisticated, remarkably intuitive program. All configuration data is provided both pre-programmedinto your instrument’s non-volitile memory, and supplied on magnetic media as a backup or for upload into the MMI.

Installation of the MMI software is fully automatic with an installation “wizard” that walks the operator through each step.Once installed the MMI software is instantly ready to provide a direct monitoring and control interface to a single GCXGas Chromatograph Transmitter or an entire network of instruments.

The MMI software provides a graphic indication of allinstruments on the network. Operators may modify tagnames and communications parameters or access aspecific instrument for input or modification of operatingconditions. Additionally all data input screens provide“scroll bar” access to every GCX on the network.Exiting the setup or display function screens is notrequired to change the instrument to be modified.

All setup functions are selectable from one convenienttabular setup menu screen. Component names, gatetimes, peak detection methods, base line correctionmode, and more are accessible from the componentsetup screen. Additional setup functions include cycletiming functions, automatic calibration frequency andtype, calculations to be performed and pseudo-compo-nent setup, analog output calibration, and Modbus setupare all provided in similar fashion. Each setup functionscreen allows both reading from the selected GCX,writing to the Controller, and the ability to save anunlimited number of instrument configurations in MMIdata files for rapid re-configuration or re-commissioningof any instrument.

The calibration data view screen allow the operator tosimultaneously view both the calculated concentrationdata from the current and previous calibration cycle,and the chromatogram for the most recent calibration.The percent change, calibration standard value, andthe method used are also displayed. The operatormay, if in “review calibration” mode, select individualcomponent values for calibration update or select toaccept all. This screen may also be used to reviewstored calibration data that has been saved to disk.

The chromatogram view screen allows the operator toselect the data plot parameters including; X and Y axisscaling, data and plot colors, gate time display, andmany other options. Chromatograms are displayed inreal time as elution is occurring, not batch updated at theend of the cycle. Also displayed is the detector beingmonitored, method in use, stream being analyzed, and acycle count timer. Systems configured for dual carrierapplications have the option of displaying a “split-screen”chromatogram view that monitors the outputs of bothdetectors 1 and 2. The chromatogram view may be usedto monitor real time data or to review chromatogramsthat have been saved to disk.

The MMI includes several comprehensive diagnosticdata views that display specific operationalparameters useful in diagnosing problems, shouldthey arise. Diagnostic data displays include indicationof power supply voltages, detector filament currents(TCD) air/fuel flows (FID), detector signal output,oven – detector – sample handling system orvaporizing liquid inject valve, and heated sample lineheater currents and temperatures. Diagnostic viewsalso include status and cycle mode indication.

The GCX man-machine-interface software is bothsophisticated and comprehensive while providing astraight forward, intuitive feel with which evenchromatography novices will be comfortable.

� All static performance characteristics are with operatingvariables constant. Specifications subject to changewithout notice.

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Unlike other GC transmitter products the GCX is at home inthe refinery or on the pipeline. This instrument, with itswide variety of configurations, available detectors, andoptional components, has the greatest applicationsversatility of any transmitter product available today. Nowfor the first time process facilities of all types can benefitfrom the reduced installation cost, reduced operating cost,and increased availability once reserved for a very fewapplications. Examples of “typical” GCX applicationsinclude:

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�Light Hydrocarbons and Olefins in Cracked Gas

�Light Hydrocarbons in Separator Overheads andBottoms

�VOC’s in Refinery Exhaust

�MTBE Purity

�Chlorinated Hydrocarbons/Aromatics in Water

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�Trace Contaminants in production or supply�Quality Assurance in Traceable Standards�Methane/Non-Methane Hydrocarbon Analysis

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�BTU, Heat Content Analysis�Compliance with ISO 6976 or GPA Standards�Custody Transfer

(When supplied with the FloBoss 407 Flow Manager fromFisher Controls, the GCX offers a complete analysissolution to AGA 3 or AGA 8 requirements)

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�Toluene, Ethyl-Benzene, and Meta-Xylene in ParaDiethylbenzene

�Impurities in Vinyl-Chloride Monomer Production�Ethyl-Benzene in Styrene�Ethylene in Demethanizer Overhead

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�Ethylene Oxide in Sterilization Applications�Methylene Chloride in Tablet Drying

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��Components: Up to 20 Maximum per stream

Calibration: Full Automatic or ManualReference to Calibration Stds.Internal NormalizationRelative Response Factors

Calibration Methods: Two

Detection Functions: Peak Height or Integrated AreaAuto Peak DetectVariable Peak Detect SensitivityBaseline to BaselineBaseline to PerpendicularPerpendicular to BaselineForced Integration

Calculation Packages:Standard- Add- Subtract- Divide- Multiply- Pseudo - component calculationcapability

Optional- BTU, ISO and GPA Standards

Streams: with Integral Zone 1, Group B, EExd AssemblyFour Streams Maximum

(3 + 1 Cal or 2 + 2 Cal)with external pneumatic SHSAssembly up to Sixteen Maximum(15 + 1 Cal or 14 + 2 Cal)

Power: 180 Watts Maximum at Start Up120 to 140 Watts NominalOver Voltage Category II Optional 24 VDC

Power CableRequirements: AC Operation (100 to 240 VDC); 16

AWG, MinimumDC Operation (24 VDC); 12 AWG,Minimum

Oven Temperature: 140 to 2840 F (60 to1400C)isothermal control to 0.1°C

Detectors: Single or Dual Carrier ThermalConductivity Detector (TCD),(minimum detectable limit)or Flame Ionization Detector (FID)

TCD DetectorAccuracy: Application Dependant

Typ. < +/- 1% Full Scale

Reproduceability: Typ. 0.25 BTU/1000 or 0.5% Full Scale

FID DetectorAccuracy: Application Dependant

Typ. < +/- 1% Full Scale

Sensitivity: 0 to 4 ppm CH4 equivalent to10,000 ppm std.

Reproduceability: Typ.< +/- 0.5% Full Scale

Sample Gas: Supply Pressure; 5-25 PSIGParticulates; < 7 microns, 0.1 uMrecommended

Carrier Gas: Supply Pressure; 10 to 30 PSIGUtilization: 40 cc/min MaximumNominal; 15 to 20 cc/min(application dependent)Dew Point; -62°C to -68°C (-80°F to -90°F)Purity; 99.999% or Better

Reproduceability: Typ. 0.25 BTU/1000 or 0.5% FullScale

Fuel Gas (FID Detector Only):Supply Pressure; 10 to 30 PSIGUtilization; 40 cc/min. MaximumNominal; 15 to 25 cc/min.(application dependent)Ultra Pure Grade Hydrogen (H2)RecommendedPurity; 99.999%Dew Point; -68°C (-90°F)Total Hydrocarbons; <1 ppm (CH4

equivalent)

Burner Air (FID Detector Only):Supply Pressure; 10 to 30 PSIGUtilization; 40 cc/min. MaximumNominal; 10 to 25 cc/min.(application dependent)Breathing Grade Air RecommendedDew Point; - 68°C (-90°F)

Vaporizing Liquid SampleInject Valve (VLSIV):Operating Temperature: 60 to 225°C (140 to 437°F)Operating Pressure: 250 PSIG MaximumInjection Volume: 0.5 to 10 uL

Methanator:Operating Temperature: 485 to 550°C (905 to 1022°F)Operating Pressure: 5 to 20 PSIGConversion Efficiency: 99.8 @ 100 cc/min Max Flow

Mounting: 4” or 6” Pipe, Rack, or Wall Mount

Weight: Base Assembly 64 Lbs (32.2 Kg)with Integral SHS 115 Lbs (52 Kg)

��Area Classification:North AmericaClass 1, Exd, e IIB (+H2), T4

EuropeCategory 2, Zone 1, EEx de IIB (+H2), T4

Compliances:USA - NRTL

- FM (pending)Canada - CSAEU - CE

- ATEX

� Ultimate lower temperature limit determined by sample system configuration.

- NAMUR-EMCAustralia /New Zealand - C-Tick (EMC)

Housing: Single cast aluminum explosion-proof andweather housing with or without integral sample handlingmodule, and increased safety junction box.Field mountable; rating NEMA 3R, IP54

Ambient Temperatures:�

15 to 1220 F(-10 to 500 C)

Relative Humidity: 5 to 100%

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Inputs/Outputs:Digital: RS 485 Multi-Drop Network

Maximum Distance; 1219 Meters(4000 Ft.)(Supports up to 36 GCX)RS 232 Serial DataMaximum Distance; 12.19 Meters(40.0 Ft.)RS 422 Modbus(Half Duplex, Modicon type 584,Remote Terminal Unit Protocol)Maximum Distance; 1219 Meters(4000 Ft.)

Analog:Current Outputs:

Up to Six Isolated 4-20 mA outputs into250 ohms Max load

Digital Outputs:Six Form B Contacts,Max Current 100 mAResistive @ 24 VDC

Digital Inputs:Six 5 to 24 VDC Signals (10 mA)

Chromatogram:Chromatogram locally available at GCXIncreased Safety Box+ 5 to –5 VDC @ 10 mA max

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Figure 2-2

Single Stream plus Calibration or for use withexternal sample system

Figure 2-1

GCX with Integral Sample Handling System

Detail 6” Pipe Mount


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Figure 2-3Typical GCX-FID Piping and Interconnect

Figure 2-4GCX with Vaporizing Liquid Sample Valve Option

G GCX PROCESS GAS CHROMATOGRAPH TRANSMITTER

Code Power Supply SelectionA 100-240 VAC UniversalB Special

Code Detector SelectionT Thermal ConductivityD Dual Carrier Thermal ConductivityF Flame IonizationM Methanator with FID

Code Oven Hardware Configurations and Application Type1 BTU ( C3+ or C4+)2 BTU (C6 +)A Vapor- Single Column / StripperB Vapor- Single Column / Back FlushC Vapor- Dual Column / StripperD Vapor- Single Column / Stripper + Single Column / StripperE Vapor- Single Column / Stripper + Single Column / Back FlushF Vapor- Dual Column / Back FlushG Vapor- Single Column / Hart Cut / StripperH Vapor- Single Column / Stripper / Detector By-passI Vapor- Single Column / Back Flush / Detector By-passJ Liquid- Single Column / StripperK Liquid- Single Column / Back FlushL Liquid- Dual Column / StripperM Liquid- Dual Column / Back FlushN Liquid- Single Column / Hart Cut / StripperO Liquid- Single Column / Stripper / Detector By-passP Liquid- Single Column / Back Flush / Detector By-passQ Liquid- Single Column / Stripper / Swab OutR Liquid- Single Column / Back Flush / Swab OutS Special

Code Applications SelectionRosemount Application Engineering Standard Application Code

XXX Special

Code Standard I/O SelectionZ NoneA Two 4-20 mA Analog Outputs, 6 Digital I/O’sB Four 4-20 mA Analog Outputs, 6 Digital I/O’sC Six 4-20 mA Analog Outputs, 6 Digital I/O’s

Code Communications OptionsZ NoneB MMI Software CompatibleC Std. ModbusD Std Modbus and MMI Compatible

Code Modem CommunicationZ None

Code Customized ConfigurationZ NoneA Modbus CustomizationB Complete System I/O ConfigurationC Modbus + System I/O Configuration

Code Sample HandlingA Rosemount SuppliedB Customer Supplied

G A T D Z Z Z A A EXAMPLE

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SHVP GCX INTEGRAL VAPOR PHASE SAMPLE HANDLING SYSTEM

Code Stream Number, Materials of Construction and Block/Bleed - Block/Vent Selections11 -00 One Stream, One Cal. 316 SS, Viton Seals12 -00 One Stream, One Cal. 316 SS, Kal Rez Seals -01 Add Block-to-Vent to the One Stream, One Cal. Selection

21 -00 Two Stream, One Cal, 316 SS, Viton Seals22 -00 Two Stream, One Cal, 316 SS, Kal Rez Seals -01 Add Block-to-Vent to the Two Stream, One Cal. Selection -10 Add Block-&-Bleed to the Two Stream, One Cal. Selection -11 Add Block-&-Bleed and Block-to-Vent to the Two Stream, One Cal. Selection

31 -00 Three Stream, One Cal, 316 SS, Viton Seals32 -00 Three Stream, One Cal, 316 SS, Kal Rez Seals -01 Add Block-to-Vent to the Three Stream, One Cal. Selection -10 Add Block-&-Bleed to the Three Stream, One Cal. Selection -11 Add Block-&-Bleed and Block-to-Vent to the Three Stream, One Cal. Selection

41 -00 Two Stream, Two Cal, 316 SS, Viton Seals42 -00 Two Stream, Two Cal, 316 SS, Kal Rez Seals -01 Add Block-to-Vent to the Two Stream, Two Cal. Selection -10 Add Block-&-Bleed to the Two Stream, Two Cal. Selection -11 Add Block-&-Bleed and Block-to-Vent to the Two Stream, Two Cal. Selection

Code Sample Handling System Heating SelectionZ None RequiredS Steam HeatingE Electric Heating

SHVP 11-00 Z EXAMPLE

NOTE: Viton and Kal Rez are registered trademarks of E.I. duPont de Numours & Co., Inc.

process gas chromatograph transmitter · the gcx is the world’s first process gas chromatograph...

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