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HYDROGEN analyser-MAIHAK make

TRAINING MODULE

HYDROGEN ANALYSER
MAKE: MAIHAK

CHECKED BY : CES INSTRUMENTATION REV 00

APS ISSUE 00
TRAINING MANUAL DATE 9/07/2000
APPROVED BY:
HSG AUTHOR: NRB

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HYDROGEN analyser-MAIHAK make

TOPICS COVERED IN THIS MODULE:

1. INTRODUCTION

2. PRINCIPLE OF OPERATION

3. SAMPLING SYSTEM

4. HARDWARE DESCRIPTION

5. CALIBRATION

6. MAINTENANCE

CHECKED BY : CES INSTRUMENTATION REV 00

APS ISSUE 00
TRAINING MANUAL DATE 9/07/2000
APPROVED BY:
HSG AUTHOR: NRB

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HYDROGEN analyser-MAIHAK make

INTRODUCTION:

The hydrogen analyser installed in our complex is detecting hydrogen based on thermal conductivity
principle . There are total 10 hydrogen analysers installed all over the RPL complex.

The following is the complete breakup of analysers spread over the complex:

CHECKED BY : CES INSTRUMENTATION REV 00

APS ISSUE 00
TRAINING MANUAL DATE 9/07/2000
APPROVED BY:
HSG AUTHOR: NRB

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HYDROGEN analyser-MAIHAK make

PRINCIPLE OF OPERATION:

Thermal conductivity principle:

Within the TCD cell are four resistive filaments , suspended in individual cavities in a metal block and
connected electrically as legs of wheatstone bridge

Two filaments work as sample side and remaining two as reference side.

When sample and reference gases flow through the cell, this gas takes away some heat from the filaments (
heat absorption of gas is depending on its thermal conductivity), which changes the temperature of
filaments.

Change in temperature of filaments also changes the resistance of the filaments.

This change in resistance causes change in current through the iflaments, which can be calibrated to detect
the conductivity and the type of gas.

CHECKED BY : CES INSTRUMENTATION REV 00

APS ISSUE 00
TRAINING MANUAL DATE 9/07/2000
APPROVED BY:
HSG AUTHOR: NRB

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HYDROGEN analyser-MAIHAK make

SAMPLING SYSTEM:

ANALYSER

6
5

4
8

CHECKED BY : CES INSTRUMENTATION REV 00

APS ISSUE 00
TRAINING MANUAL DATE 9/07/2000
APPROVED BY:
HSG AUTHOR: NRB

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HYDROGEN analyser-MAIHAK make

The detailed description of all the parts mentioned in the above figure is as below:

1. Sampling point: The point where from sample is being taken for analysis. In the analyser used
in our complex, the sample is taken from the stack and is usually at a height of 5-6m. The
sample is being pumped into the analyser with the help of vacuum pump

2. Pressure reducing device: Brings down the sample gas pressure down to the allowable
pressure

3. Gas lines: the gas lines must be made from stainless steel tubes.

4. Dust filter: an external dust filter is used to avoid the contamination in the sample

5. Analyser bypass: increases the sample gas flow to the analyser in order to have a quick
response time.

6. Flowmeter: to set the correct sample gas flow through the analyser.

7. Flame arrestor: To prevent flames from entering the gas analyser.

8. Test gas feed: Used to verify the operation of the analyser with the help of standard zero and
span calibration test gases.

CHECKED BY : CES INSTRUMENTATION REV 00

APS ISSUE 00
TRAINING MANUAL DATE 9/07/2000
APPROVED BY:
HSG AUTHOR: NRB

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HYDROGEN analyser-MAIHAK make

HARDWARE DESCRIPTION:

The main CPU board processes the electronic signal , manipulates it according to the parameters
chosen by the user, stores and remembers all variables/options, calculates calibration
parameters, determines hydrogen concentrations and output those concentrations to the front
LCD and analog terminals. It also controls temp. of optical bench to approx. 55 deg.C and offers
the user a variety of status and troubleshooting of outputs.

CHECKED BY : CES INSTRUMENTATION REV 00

APS ISSUE 00
TRAINING MANUAL DATE 9/07/2000
APPROVED BY:
HSG AUTHOR: NRB

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HYDROGEN analyser-MAIHAK make

Calibration / validation:

The analyser has three different types of calibration procedures:

1. Automatic calibration,
2. Manual calibration with automatic feed of the test gases,
3. Manual calibration with manual feed of the test gases.

Note: When the control input “Service/Cal.” is disabled the menu functions for
calibration cannot be accessed.

The applied method for calibration is the manual calibration (3) with manual feed of the
test gases.

Preparation before calibration:

The following items need to be programmed before a manual calibration can be
performed:
?? Nominal calibration gas values
?? Span delay time
?? Calibration measuring time

Setting the nominal calibration gas values:

The nominal values of the calibration gases can be set as reference value during the
calibration. During the actual manual calibration the values may be changed e.g. when
another calibration bottle is applied.
?? Call-up menu 63, : main menu ? calibr. parameter,

?? Select zero gas or a test gas (A,B,C). The current settings are displayed.

Note: For the test gases, which are not applicable, make sure that “—“ is entered,
a zero value will result in a wrong (multi-point) calibration !

?? Select gas pump – off and select the desired measuring component and enter the
reference value as indicated on the gas cylinder analysis certificate,

CHECKED BY : CES INSTRUMENTATION REV 00

APS ISSUE 00
TRAINING MANUAL DATE 9/07/2000
APPROVED BY:
HSG AUTHOR: NRB

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HYDROGEN analyser-MAIHAK make

Setting the span delay time :

This is in fact the response time of the analyser system including the sample
conditioning system.

?? Call-up menu 6361 , : main menu ? settings ? calibr. parameter ?

autom. calibration ? span delay time,

?? Set the span delay time in sec. Standard setting is 30 sec.

Setting the calibration measuring time :

This time starts after the span delay time. It is used to measure the calibration gas value
by gathering a number of measured values and computing the average.
?? Call-up menu 6362 , : main menu ? settings ? calibr. parameter ?
autom. calibration ? calibration measuring time,

?? Set the calibration measuring time in sec. Standard setting is 180 sec.

Manual calibration:
?? Call-up main menu 4 - 2 and just follow the instruction steps as displayed.

?? Shut off the sample inlet valve before letting the calibration gas pass through
analyser .

?? Make sure to set the correct flow rate for the cylinder (10-100 l/hr)
?? The pressure in the line should be 0.1-1 bar

CHECKED BY : CES INSTRUMENTATION REV 00

APS ISSUE 00
TRAINING MANUAL DATE 9/07/2000
APPROVED BY:
HSG AUTHOR: NRB

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HYDROGEN analyser-MAIHAK make

MAINTENANCE:

Maintenance of the Maihak CO2 /O2 stack gas analyser is mainly limited to the daily visual
checks of the sample conditioning system and the proper settings for the sample flow through the
analyser.
The application on a stack-sample, which normally contains a high dust load, high temperatures
and a high amount of water vapour, establishes extensive sample conditioning requirements, this
because of the analyser parts are sensitive to clogging, condensation and oxidation, like both
sample cells of this analyser.
For these reasons the regular inspection of the sampling conditions is essential.

Regular preventive checks:

Daily visual checks: (see also Daily visual check sheet)

??Check the presence of sample flow to the analyser

??Check the conditions of the analyser gas connections,

??Check the function “lamp”, which should be illuminated green, if the indication is red,
observe the display message and take appropriate action,

??Check the service “lamp”, which should not be illuminated. If the lamp is on, observe
the display message and take appropriate action,

Weekly check:

??Check the presence of any fault condition by means of displaying “Status check – 21’

??Check working condition of sampling system components viz. dryer, cooler, filter

??Check presence of steam used for heating sample lines.

CHECKED BY : CES INSTRUMENTATION REV 00

APS ISSUE 00
TRAINING MANUAL DATE 9/07/2000
APPROVED BY:
HSG AUTHOR: NRB

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HYDROGEN analyser-MAIHAK make

Six-months check:

??Check all gas channels for a possible leakage (see next section)

??Check / replace internal safety filter.

Leak check:

1. Close the inlet- and outlet-valve of the fast loop,

2. Wait till the analyser flow has stopped,

3. Switch the analyser to the zero calibration mode, call up via the main menu
respectively 4 – 2 – 1

4. Select zero gas.

5. Open the zero gas bomb and set the pressure regulator to zero setting (no analyser
flow) and keep the span-gas bottle closed (pressure should be zero),

6. Disconnect the outlet connection of the analyser and connect a water-filled U-tube
(height about 1.5 m) to the analyser outlet,

7. Carefully rise the setting of the bomb regulator to a setting just below 2 psig, so the
water U-tube will indicate about 1400 mm wc,

8. Then close the bomb valve on the zero-gas bomb thoroughly,

9. Wait and observe the pressure indication before the pressure regulator and the water
column indication at the U-tube.

10. If there is a leakage, the pressure will drop with a rate depending on the size of the
leakage.

11. To return to normal operation, follow the steps 1 to10 in reverse order.

CHECKED BY : CES INSTRUMENTATION REV 00

APS ISSUE 00
TRAINING MANUAL DATE 9/07/2000
APPROVED BY:
HSG AUTHOR: NRB

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HYDROGEN analyser-MAIHAK make

Note: Maihak specifies a maximum pressure drop (allowable leakage) of 5 mm water
column each 4 minutes.

Locate the leakage by means of “SNOOPY” or water mixed with soap.

Be careful when introducing the water into the analyser ! Switch off the analyser first
and avoid contact with the electronics

CHECKED BY : CES INSTRUMENTATION REV 00

APS ISSUE 00
TRAINING MANUAL DATE 9/07/2000
APPROVED BY:
HSG AUTHOR: NRB

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