GAH Series ATEX compliant gas analyzer system hydrogen-cooled alternators - ABB MEASUREMENT & ANALYTICS | DATA SHEET
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— ABB MEASUREMENT & ANALY TICS | DATA SHEET GAH Series ATEX compliant gas analyzer system hydrogen-cooled alternators
2 GAH 200 SE RIE S AT EX COMP LI ANT ANALY ZE R SYSTE M | DS/GAH-E N RE V. A
G AH 200 S E RIE S AT EX COMP LI ANT ANALY ZE R SYSTE M | DS/GAH-E N RE V. A 3
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General Purge gas
The GAH range of instruments is designed to provide reliable To complete the system the GAH series also incorporates a
and accurate hydrogen purity and purge gas measurement to purge gas analyzer.
ensure the safe and efficient operation of hydrogen cooled
During commissioning and de-commissioning of a system it
turbo-generators.
is essential that the hydrogen is safely introduced and
removed from the turbo-generator.
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To avoid an explosive mixture of air and hydrogen during
Hydrogen purity commissioning, air must first be purged from the system by
Modern high capacity turbo-generators need to be cooled an inert gas; carbon dioxide is in common use for this
efficiently. Hydrogen, with a thermal conductivity of about purpose although argon or nitrogen are gaining popularity.
seven times that of air, is in general use as the coolant. The hydrogen coolant is then introduced and replaces the
purge gas.
Any drop in hydrogen purity during operation of the machine
has two adverse effects: To decommission the turbo-generator the purge sequence is
reversed.
• The first, and most important, is to compromise the safe
operation of the generator. Accurate measurement of
hydrogen purity is essential to provide an early warning of
a potentially explosive mixture of hydrogen and air.
• The second is the economic impact of reduced efficiency.
To increase plant performance and control generating cost
per megawatt, turbine generators must perform with
optimum efficiency. A drop in hydrogen purity causes
additional windage losses and consequently reduces
generator efficiency.
4,500
4,000
800 MW unit
3,500
400 MW unit
Financial loss, $US/day
3,000
2,500
2,000
1,500
1,000
500
0
100 99 98 97 96 95 94 93 92 91
% hydrogen purity
Figure 1 Typical cost of decreased hydrogen purity4 GAH 200 SE RIE S AT EX COMP LI ANT ANALY ZE R SYSTE M | DS/GAH-E N RE V. A
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Katharometer
Principle of operation Zener barrier devices
The GAH range of gas analyzers utilizes thermal conductivity Zener barrier devices are included in the display monitor
as its principle for measurement. When a constant current is enclosure to prevent any dangerous electrical feedback from
passed through an electrical conductor surrounded by gas in the transmitters to the hazardous area.
a chamber, the temperature rises to a point of thermal
Power supply
equilibrium. Provided radiation, convection and
The 4234 power supply units provide the analyzer assemblies
end‑conduction losses are minimized, the temperature of the
with an intrinsically safe (IS), stable constant current. These
conductor depends upon the heat loss by conduction through
power units must be installed in a ‘safe’ area but the current
the gas. The temperature attained is therefore related to the
output from them may be transmitted to the katharometers
thermal conductivity of the surrounding gas and hence the
in the hazardous area.
resistance of the wire is a function of the thermal
conductivity. Gas analysis panel
The 6548 gas analysis assemblies are fitted with a thermally
The katharometer comprises a wheatstone bridge, each arm
lagged katharometer, a needle flow-control valve, a flow
of which contains a fine, glass-coated, platinum wire. One pair
gauge and a drying chamber.
of parallel arms is sealed in a reference gas of known thermal
conductivity and the other pair is exposed to the sample gas. Sample gas low-flow alarms
A constant current is passed through the bridge network. Any (Only available when system is ordered complete with cubicle)
difference between the thermal conductivities of the
Optional intrinsically safe, sample-gas low-flow alarms can be
reference and sample gases causes an imbalance of the
fitted in the Cubicle and connected to the sample gas flow
bridge. This imbalance is a function of the difference in
meter. These are used to warn operators of leaks or
thermal conductivities of the two gases so the analyzer can
blockages in the sample line.
be calibrated directly in terms of the percentage of one gas to
another. GAH100 single 3-range analyzer
Simple solution for purity and purge measurement
Product description
comprising:
A complete system comprises:
• One gas analysis panel measuring hydrogen purity plus
• Display monitor
the purge gas ranges.
• One (or two) gas analysis panels
• One power supply.
• One (or two) power supply units
• One display monitor containing one digital transmitter
Display monitor that displays the hydrogen purity range and the purge
The 6553 display monitor includes one or two 4689 digital gas ranges. The range selector switch controls the range
transmitters, the range selector switch (excluding GAH200), to be displayed.
katharometer remote zero adjustment control and zener
GAH200 dual 3-range analyzer
diode safety barriers.
100 % redundancy and validation version comprising:
Digital transmitters • Two gas analysis panels each measuring hydrogen purity
The 4600 series universal transmitter provides the operator plus the purge gas ranges.
interface and communication to other devices. The signal • Two power supply units.
from the sensing system is converted by the transmitter and • One display monitor containing two digital transmitters.
the measurement is presented on a large, easy-to read, Both the upper and the lower digital transmitters display
backlit liquid crystal display. This display is used in the hydrogen purity range and the two purge gas ranges.
conjunction with the four tactile membrane keypads to Each digital transmitter has its own range selector switch
prompt the user through the programming procedures. The to control the range to be displayed.
transmitter is fitted with two-step alarms for falling hydrogen
Operating range
purity.
Range for hydrogen purity:
• 85 to 100 % H2
• 80 to 100 % H2 user selectable
Range for purge gas:
• 0 to 100 % hydrogen in purge gas*
• 0 to 100 % air in purge gas*
• Carbon dioxide standard; argon or nitrogen
also available.
* Carbon dioxide standard; argon or nitrogen also availableG AH 200 S E RIE S AT EX COMP LI ANT ANALY ZE R SYSTE M | DS/GAH-E N RE V. A 5
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Analyzer panels
The gas sample may be vented to atmosphere or returned to
the generator at an elevated pressure. This panel is equipped
with fittings suitable for such duties and is pressure tested to
10 bar (gauge).
Note. As no certification exists for measurements at
pressures above 1 bar absolute (nominal), it must be
understood that the stated I.S. certification does not cover
use at higher pressures.
Hazardous area Safe area
Analyzer panel Power supply units
(6548) (4234) 115 or 230 V AC
L Monitor
(6553)
N
80 or 85 % to 100 % in air
0 to 100 % H2 in purge gas* E
0 to 100 % air in purge gas*
CM30 indicator
115 or 230 V AC
Figure 2 GAH100 single 3-range analyzer system
Hazardous area Safe area
Analyzer panel Power supply units
(6548) (4234) 115 or 230 V AC
L
N
80 or 85 % to 100 % in air
0 to 100 % H2 in purge gas* E
Monitor
0 to 100 % air in purge gas*
(6553)
L
CM30 indicator
N
Analyzer panel E
(6548)
CM30 indicator
115 or 230 V AC
80 or 85 % to 100 % in air
0 to 100 % H2 in purge gas*
0 to 100 % air in purge gas*
Figure 3 GAH200 dual 3-range analyzer system
* Carbon dioxide standard; argon or nitrogen also available6 GAH 200 SE RIE S AT EX COMP LI ANT ANALY ZE R SYSTE M | DS/GAH-E N RE V. A
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Typical installation
The schematic diagram below shows typical arrangements.
Analyzer panel
Tapping
point (6548)
Sample filters
Normally closed *
Analyzer panel
Note. All valves except * fully (6548)
open during operations GAH200 systems only
Sample return
to generator
Figure 4 System with non-vented sampleG AH 200 S E RIE S AT EX COMP LI ANT ANALY ZE R SYSTE M | DS/GAH-E N RE V. A 7
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Specification
6553 gas monitor Digital I/O
Approvals Number
• CENELEC approved 6
• [Ex ia Ga] IIC (–20°C ≤ Ta ≤ +40°C)
Type
• BASEEFA Certificate No. BAS 01 ATEX 7043
User-programmable as input or output
• II (1)G
Minimum input pulse duration – 125 ms
• EN61010-1:2010 compliant
Input
Ranges
• Volt-free or 24 V DC
• 80 % or 85 % to 100 % H2 in air
• 1 – signal 15 to 30 V
• 0 to 100 % H2 in purge gas*
• 0 – signal 3 to 5 V
• 0 to 100 % air in purge gas*
• Conforms to IEC61131-2
Range selector switch positions (when fitted)
Output
1 percentage by volume, hydrogen in air
• Open collector output
2 percentage by volume, hydrogen in purge gas*
• 30 V, 100 mA max. switched
3 percentage by volume, air in purge gas*
• Conforms to IEC61131-2
Accuracy (display units)
Update rate
± 0.25 % of scale span
125 ms
Ambient temperature range
Relays
0 to 40 °C (32 to 104 °F)
No. of relays
Power supply 4
110 /120 V AC or 200/220/240 V AC, 50/60 Hz
Contact rating
(two separate versions)
5A, 240 V
Fuse rating
Update rate
F1/F2 500 mA, 250 V AC rated 1500 A @ 250 V AC,
125 ms
HRC, ceramic, fast blow
Set points
Power consumption
No. of set points
30 VA approximately
4
Outline dimensions
Set point adjustment
290 × 362 × 272 mm (11.4 × 14.25 × 10.9 in)
Programmable
Weight
Set point hysteresis
12 kg (26.4 lb)
±1 % fixed
Environment
Local set point annunciation
Sheltered interior, 0 to 90 % RH
Red LED
Analog outputs
No. of retransmission signals
2 fully isolated
Output current
0 to 10 mA or 0 to 20 mA programmable
Accuracy
±0.25 % FSD ±0.5 % reading
Resolution
0.1 % at 10 mA, 0.05 % at 20 mA
Max. load resistance
750 ohm (20 mA max.)
* Purge gas options include CO2 (carbon dioxide), N2 (nitrogen), Ar (argon)8 GAH 200 SE RIE S AT EX COMP LI ANT ANALY ZE R SYSTE M | DS/GAH-E N RE V. A
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…Specification
4234 power supply unit 6548–000 katharometer analyzer panel
Approvals Approvals
• CENELEC approved • CENELEC approved
• [Ex ia Ga] IIC (–20°C ≤ Ta ≤ +55°C) • Ex ia Ga IIC (–20°C ≤ Ta ≤ +55°C)
• BASEEFA Certificate No. BAS 01 ATEX 7041 • BASEEFA Certificate No. BAS 01 ATEX 1042
• II (1)G • II 1G
• EN61010-1:2010 compliant • Model 6548–000 incorporating Model 6548–001 (H2 and
Power supply purge gas) katharometer unit
115 V AC 50/60 Hz (4234501) or
Power supply
230 V AC 50/60 Hz (4234500)
350 mA DC, from 4234500 or 4234501 power supply unit
Power consumption
Signal output
30 W max.
0 to 10 mV for each range (air in N2 1.0 mV)
Fuse rating
Accuracy
• T250 mA 250 V AC rated 1500 A HRC ceramic, 250 V AC
± 2 % of scale span, each range
rated
± 5 % of scale span, air in N2
• 20 x 5 mm
DC output Dead time
350 mA stabilized ±0.14 % Typically 5 s
Load conditions Response time
1 Katharometer 13 ohm max. Typically 40 s for 90 % step change at katharometer
Interconnecting cable 2 ohm max. (tubing and drying chamber introduce extra delays)
Ambient temperature range Ambient temperature
–20 to 55 °C (–4 to 131 °F) 55 °C (131 °F) max.
0 °C (32 °F) min.
Supply variations
±15 V (115 V supply) or ±30 V (230 V supply) 46 to 64 Hz Sample connections
Compression couplings:
Regulation
• 6 mm OD tube
Within ± 0.5 % for:
Sample pressure
• Load variation of ± 15 % Minimum 125 mm H2O
• Supply variation of ± 15 %
• Ambient temperature variation of ± 20 °C (36 °F) Sample temperature
• ±4 Hz frequency variation 0 to 55 °C (32 to 131 °F)
Ripple Normal sample flowrate
Less than 0.5 % of set output peak/peak across a 10 ohm 100 to 150ml/min.
load
Maximum gas flowrate
Stability 250 ml/min
Within ± 0.7 % of initial setting, over period of 1 month
Minimum gas flowrate
with load resistance, supply voltage and ambient
50 ml/min
temperature at nominal stated values
Outline dimensions
Overall dimensions
610 × 305 × 152 mm (24 × 12 × 6 in.)
160 × 170 × 110 mm (6.3 × 6.7 × 4.3 in.)
Weight
Weight
8.6 kg (18.9 lb)
2.12 kg (4.8 lb) approx.
Environment
Environment
Sheltered interior
Sheltered interiorG AH 200 S E RIE S AT EX COMP LI ANT ANALY ZE R SYSTE M | DS/GAH-E N RE V. A 9
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Overall dimensions
Dimensions in mm (in.)
610 (24) 148 (6.04)
50 (2.04)
38 (1.55)
572 ±0.3 (23.35 ±0.01) 19 (0.77)
Gland for Ø7 to 10.5 (0.28 to 0.43) cable Outlet
Coupling for Ø6 (0.24) tube
Ø6 (0.24) tube
Coupling for
267 ±0.3 (10.9 ±0.01)
305 (12.45)
233 (9.5)
98 (4) Inlet
179 (7.3)
10 (0.41)
19 (0.77) 112 (4.57) 4 fixing holes Ø 10 (0.41)
Figure 5 Katharometer analyzer panel assembly (Model 6548–000)
290 (11.84) 30 (1.22) 272 (11.1) 160 (6.3) 110 (4.3)
140 (5.5) 83 (3.27)
117 (4.6)
362 (14.8)
Mounting
345 (14.08)
panel
thickness
0 – 20
(0 – 0.82) Cable entry
170 (6.7)
110 (4.3)
glands
Cable
entries
Mounting
panel
display
face
Katharometer Power and signal
intrinsically conventional
circuits 4 fixing slots
safe circuits
20 (0.8) long x 10 (0.4) wide
Figure 6 Model 6553 monitor) Figure 7 Intrinsically safe power supply unit (Model 4234500 or 4234501)
Sales Service Software10 GAH 200 SE RIE S AT EX COMP LI ANT ANALY ZE R SYSTE M | DS/GAH-E N RE V. A
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Ordering information
ATEX compliant gas analyzer for hydrogen-cooled alternators
Gas options – system 1
Gas options – system 1 Gas options – system 2
Power Approvals Range 1 Optional Optional Range 1 Optional Optional Cubicle Flow Language
supply range 2 range 3 range 2 range 3 alarms
GAH200 X X XX XX X XX XX X XX XX X XX XX X XX XX X XX XX X X X XX
Power supply
115 V A
230 V B
115 V Intrinsically Safe C
230 V Intrinsically Safe D
Approvals
ATEX Class 1 Zone 1 1
cSGSus 2
Gas A
Air A0
Argon A1
Carbon Dioxide C2
Methane C4
Hydrogen H1
Helium H2
Nitrogen N1
Oxygen O2
Special Z9
Gas B
Air A0
Argon A1
Carbon Dioxide C2
Methane C4
Hydrogen H1
Helium H2
Nitrogen N1
Oxygen O2
Special Z9
AB range
0 – 100 % 1
80 – 100 % 2
85 – 100 % 3
Special 9
Gas C
Not needed Y0
Air A0
Argon A1
Carbon Dioxide C2
Methane C4
Hydrogen H1
Helium H2
Nitrogen N1
Oxygen O2
Special Z9
Gas D
Not needed Y0
Air A0
Argon A1
Carbon Dioxide C2
Methane C4
Hydrogen H1
Helium H2
Nitrogen N1
Oxygen O2
Special Z9
CD range
Not needed 0
0 – 100 % 1
80 – 100 % 2
85 – 100 % 3
Special 9
Gas options – system 1 continued…G AH 200 S E RIE S AT EX COMP LI ANT ANALY ZE R SYSTE M | DS/GAH-E N RE V. A 11
Gas options – system 1 Gas options – system 2
Power Approvals Range 1 Optional Optional Range 1 Optional Optional Cubicle Flow Language
supply range 2 range 3 range 2 range 3 alarms
GAH200 X X XX XX X XX XX X XX XX X XX XX X XX XX X XX XX X X X XX
Gas E
Not needed Y0
Air A0
Argon A1
Carbon Dioxide C2
Methane C4
Hydrogen H1
Helium H2
Nitrogen N1
Oxygen O2
Special Z9
Gas F
Not needed Y0
Air A0
Argon A1
Carbon Dioxide C2
Methane C4
Hydrogen H1
Helium H2
Nitrogen N1
Oxygen O2
Special Z9
EF range
Not needed 0
0 – 100 % 1
80 – 100 % 2
85 – 100 % 3
Special 912 GAH 200 SE RIE S AT EX COMP LI ANT ANALY ZE R SYSTE M | DS/GAH-E N RE V. A
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…Ordering information
…ATEX compliant gas analyzer for hydrogen-cooled alternators
Gas options – system 2
Gas options – system 1 Gas options – system 2
Power Approvals Range 1 Optional Optional Range 1 Optional Optional Cubicle Flow Language
supply range 2 range 3 range 2 range 3 alarms
GAH200 X X XX XX X XX XX X XX XX X XX XX X XX XX X XX XX X X X XX
Gas A
Air A0
Argon A1
Carbon Dioxide C2
Methane C4
Hydrogen H1
Helium H2
Nitrogen N1
Oxygen O2
Special Z9
Gas B
Air A0
Argon A1
Carbon Dioxide C2
Methane C4
Hydrogen H1
Helium H2
Nitrogen N1
Oxygen O2
Special Z9
AB range
0 – 100 % 1
80 – 100 % 2
85 – 100 % 3
Special 9
Gas C
Not needed Y0
Air A0
Argon A1
Carbon Dioxide C2
Methane C4
Hydrogen H1
Helium H2
Nitrogen N1
Oxygen O2
Special Z9
Gas D
Not needed Y0
Air A0
Argon A1
Carbon Dioxide C2
Methane C4
Hydrogen H1
Helium H2
Nitrogen N1
Oxygen O2
Special Z9
CD range
Not needed 0
0 – 100 % 1
80 – 100 % 2
85 – 100 % 3
Special 9
Gas options – system 2 continued…G AH 200 S E RIE S AT EX COMP LI ANT ANALY ZE R SYSTE M | DS/GAH-E N RE V. A 13
Gas options – system 1 Gas options – system 2
Power Approvals Range 1 Optional Optional Range 1 Optional Optional Cubicle Flow Language
supply range 2 range 3 range 2 range 3 alarms
GAH200 X X XX XX X XX XX X XX XX X XX XX X XX XX X XX XX X X X XX
Gas E
Not needed Y0
Air A0
Argon A1
Carbon Dioxide C2
Methane C4
Hydrogen H1
Helium H2
Nitrogen N1
Oxygen O2
Special Z9
Gas F
Not needed Y0
Air A0
Argon A1
Carbon Dioxide C2
Methane C4
Hydrogen H1
Helium H2
Nitrogen N1
Oxygen O2
Special Z9
EF range
Not needed 0
0 – 100 % 1
80 – 100 % 2
85 – 100 % 3
Special 9
Cubicle/Flow alarms/Language options
Cubicle
Not needed Y
Included A
Flow alarms
Not needed 0
Flow alarms kit 1
Flow alarms 2
Language
English M5
German M1
Italian M2
Spanish M3
French M414 GAH 200 SE RIE S AT EX COMP LI ANT ANALY ZE R SYSTE M | DS/GAH-E N RE V. A — Accessories and spares Model 6553 Display unit Description Part number Fuse, 500 mA 250 V AC rated F 20 × 5 mm ceramic cartridge HBC (1500 A) 250 V AC 0231 601 Upper function selector switch – AK103 and AK102 006553 511 Lower function selector switch – AK102 006553 512 Display units carbon dioxide purge 4689/502 Display units argon purge 4689/505 Zener diode safety barrier devices MTL 7055ac 0248 297 Zener diode safety barrier devices MTL 7755ac 0248 296 Low flow alarm (if fitted) | Zener diode safety barrier devices MTL 767+ 0248 298 Model 4234 Power supply unit (PSU) Description Part number Nominal 230 V PSU 4234/50000 Nominal 115 V PSU 4234/50100 Fuses Description Part number F2/F3 – T250 mA/1500 A 250 V AC HBC ceramic cartridge 20 × 5 mm 0231577 F1 – 400 mA cartridge 0231555 Katharometer analyzer panel Description Part number Drying chamber cylinder – acrylic 006525 720 Drying chamber cylinder – stainless steel 006548 111 Drying chamber complete – acrylic 006548 003 Drying chamber complete – stainless steel 006548 110 Flowmeter (without flow alarms) 0216 485 Flowmeter (with flow alarms) 0216 557 Metering valve 0216 484 Katharometer unit 006548 001 Drying chamber refurbishment kit 006548 007 Granular anhydrous CaCl2 006537 580
G AH 200 S E RIE S AT EX COMP LI ANT ANALY ZE R SYSTE M | DS/GAH-E N RE V. A 15
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ABB Measurement & Analytics
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Rev. A 01.2021
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