Course Overview

Analytical instruments used for online chemical analysis of process streams or plant environments are generally called Process Analyzer Systems or Quality Measuring Instruments. Reliable online analytical data is crucial for a safe and efficient operation is not limited to the Oil & Gas and Chemical Industry but also for Pharmaceutical, Power Generation and other industries.Legislative requirements, economic as well as health and safety, emissions control and energy conservation are setting increasing stringent limits for reliable analyzer data which may result in huge losses or fines to the operating company.We focus on all issues related to online Chromatography type analysis ranging from the basic principles, Sample Injection techniques, Analysis Columns, Applied Detector systems and particular Industrial Chromatographic configurations.Other important subjects are specific on-line PGC systems and practical tools for Performance Monitoring and Troubleshooting.Also there are two subjects discussed that are of still growing importance for the Environment; the Continuous Emission Monitoring Systems, where the main part of the applied analysis is covered by Spectroscopy.

Course Objectives

Attendees will gain an understanding of:

• Describe the purpose, operation and application of a Process Gas Chromatographic (PGC) systems, Quality Monitoring systems as well as Spectroscopic Analyzer systems,
• Identify and explain the different types of Industrial PGC applications and Emission Monitoring (CEMS),
• Understanding of the basic rules and tools for Analytical Accuracy, Performance & Quality Assurance.

Who Should Attend?This course is intended for all who are regularly involved with Process GC and CEMS systems like Instrument Technicians and Engineers, Production, Operation and Laboratory staff.

Course Contents

Module (01) Principles of Gas Chromatography

• Introduction
• Combinations of GC analysis
• What is Chromatography
• Retention phenomena
• Separation factors
• Retention factor
• Types of Chromatographic columns
• Band broadening and column efficiency
• Theoretical Plate Model
• Temperature influence on separation
• Van ‘Deemter’ efficiency curve
• Selection of the type of carrier gas
• Peak Selectivity and Resolution
• Base line properties, Noise and LOD

Module (02) Chromatographic Analysis Columns

• Types of applied analysis columns
• How to specify an GC column
• GSC – Molsieves column application
• Types of open tubular Capillary columns

Module (03) Types of applied PGC Detectors

• Types GC detectors based on their Selectivity
• Main types of PGC Detection systems
• Thermal Conductivity Detector and measurement
• Flame Ionization Detector
• Dynamic Range of Detectors
• Application of Make-up gas
• Electron Capture Detector
• Flame Photometric Detector
• Nitrogen Phosphorous Detector
• Detector and Relative Response Factors

Module (04) Sample Injection techniques

• Applied Sample online Injection systems
• Online Sample Injection using rotary valves
• Liquid injection valve technique
• Split versus Split less injection
• Headspace and PTV Injection system

Module (05) Peak Detection and Quantitation Methods

• Definition Relative Response Factor
• System factor and Calibration Factor
• Applied Peak Integration Methods
• Integration Basics
• Generally applied Peak Integration Parameters
• Peak Sampling rate and Threshold settings
• Some important Integration notes
• Peak Integration issues and system features
• Analysis Data Processing
• Types of Calibration Methods
• Normalization issues
• Internal / External Standard calibration

Module (06) PGC Utilities

• Generally, requirements for Utility Gases
• Installation of filter traps
• Carrier Gas purity
• Tubing and Regulators
• Moisture filtration
• Basics principles for Pressure and Flow control
• Electronic Pressure and Flow Control

Module (07) GC Analysis & Valve Configurations

• Multi-port configuration valves
• Natural Gas configuration
• The GC Control system
• Variable conditions to accommodate the analysis system
• Temperature Programming
• Programming the analysis methods
• Stripping / Back-flushing
• Hart-cutting , Trapping and Parking

Module (08) Measurement Accuracy and Quality Assurance

• Accuracy, Bias and Precision
• Variance and Standard Deviation
• Normal Distribution
• Repeatability and Reproducibility
• Types of measurement errors
• Set-up Control Chart tool for Performance Monitoring
• Statistical Decision Rules
• Reproducibility Rate

Module (09) PGC Troubleshooting

• Best Practices for troubleshooting
• Summary of main problems
• Baseline disturbances noise, spiking, drift etc.
• Peak shape distortion
• Fronting and Tailing peaks
• Ghost peaks
• Diagnostic features

Module (10) Heating Value Measurements

• Introduction Calorimetry
• Types of Calorimeters
• Determination of Heating Values using the Ultimate GC method
• Dulong Equation
• Gross Calorific determination of Natural Gas by online PGC according to ISO 6976
• ISO 6976 - Calculations derived from Natural Gas analysis
• Higher and Lower Heating Value
• Wobbe Index and CARI
• Online Wobbe Index analyzer
• NMR application

Module (11) Example Transmitter type ABB PGC 1000 features and Configuration

• PGC features
• Operator Interface
• Maintenance
• Historical Data
• Analysis parameter Configuration
• Automatically Peak Gating
• Manual Peak Gating methods
• Calibration

Module (12) Introduction to Continuous Emission Monitoring Systems - CEMS 

• Applications and Specifications of CEMS
• Directives and approvals
• Plain English Guide – EPA 40
• Quality Assurance Levels
• Who are the EPA and EMC?
• Monitoring requirements
• Essential parts of a CEMS systems
• To who do the requirements apply?
• Monitoring measurement requirements
• What are the Certification requirements?
• Relative Accuracy Test Audit – RATA
• Quality Assurance and Emission reporting
• CEMS Sampling systems methods
• Cold and Hot extractive systems
• Spectroscopic type of CEMS analyzers
• TDLAS application
• CEMS Suppliers

Module (13) Spectroscopic Analysis IR, UV and FTIR

• Types of Spectral Absorptions
• Spectral Ranges
• Relation frequency and wavelength
• Diffraction methods
• Principles & Techniques applied
• Types of Spectroscopy
• Lambert Beer’s Law
• NIR spectrum
• Industrial Non Dispersive IR analysis
• UV analysis
• FT-IR and FTNIR
• How are FTIR results obtained
• Practical Differences FTIR and IR
• Raman Spectroscopy
• Spectrometers for CEMS
• NMR application

Module (14) PEMS versus CEMS

• What are PEMS ?
• What are PEMS Challenges ?
• List of PEMS advantages compared to CEMS
• Requirements for PEMS

Module (15) Siemens Maxum - Valves & Analysis Configuration (Optional)

• PGC – Workstation / Controllers
• Temperature Measurement & Control
• Applied type of Valves, Solenoid, Rotary 6 / 10 ports
• Sample injection system
• Multi-port Configuration Valves
• Valve-less switching technique
• Siemens types GC Diaphragm Valves
• Liquid Injection Valve
• EPC Pressure Control Module
• Siemens type TCD
• Parallel Chromatography
• Drawing Notes
• Backflush Column Configuration
• Tools to monitor the separation process
• Flow settings procedure
• Operational checking
• Calibration
• Analyzer Project Specs
• Actual Vapour & Liquid sample take off configuration
• Streams Data
• Chromatograms

Module (16) EZ Chrom Operational Manual (Optional)

• Instrument Setup
• Development of Analysis Method
• Sequence setup / Stream selection
• Peak Tables and Integration Parameters
• Prepare a Method for Calibration
• Adding Integration Options
• Baseline settings
• Running a Sample