SIEMENS Automation & Drives Technical Support Information No. 91 September 2003 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 1 of 1 Information zu / to Maxum II Methanator Spülung und Oxydation Zusammenfassung Der Maxum II Methanator wird mittels der Gönnheimer APU gespült um die Temperatur-Betriebssicherheit zu erfüllen. Wie auf dem Aufkleber angebracht am Maxum II aufgeführt, darf der GC erst geöffnet werden, nachdem sichergestellt ist, dass die Umgebung frei von feuergefährlichem Material bzw. erst nachdem 30 Minuten zuvor alle elektronischen Bauelemente abgeschaltet wurden. Die hohe Spülrate sollte mindestens 5 Minuten und bei mindestens 10 psig Ofenluft verwendet werden. Maxum II Methanator Purge and Oxidation Purging the Maxum II Methanator The Maxum II Methanator is purged, with the EC purge system, to meet the safety temperature rating of the analyzer. As stated on the tag on the Maxum II with a Methanator, the analyzer shall not be opened unless the area is known to be free of flammable material or all devices in the analyzer have been turned off for at least 30 minutes. This allows the heater in the methanator to cool down to a safe level. To ensure the Methanator is purged of possible flammable material, fast purge needs to run for at least 5 minutes. The following text is on a tag which is attached to all Maxum II analyzers with a Methanator: When operating this unit in a Div 2 area when equipped with Methanator Model 2021601: This enclosure shall not be opened unless the area is known to be free of flammable material or unless all devices within have been deenergized for at least 30 minutes. Power shall not be restored after enclosure has been opened until the "FAST PURGE" has been on for 5 minutes with an "OVEN AIR" of at least 10 psig. Background: The Optichrom Methanator was not purged because its housing is an explosion proof enclosure. Purging the Maxum II Methanator keeps explosive gasses from reaching the hot surfaces inside the Methanator. Attached is a pdf which includes; the assembly drawing for the Maxum II Methanator, a section from the manual and the installation drawing for the Methanator installation kit. Refer to TSI No. 82 for additional informations about Methanator catalyst in oxidized state! Spare Parts 2021601-001 - Maxum II Methanator, Temperature Controlled 115/230 VAC (complete assembly) 1621004-012 - Heater, Cartridge 1622001-020 - RTD, Push-In Style © SIEMENS AG Karlsruhe A&D PI 2 AS 2 Niko Benas Tel. +49 721 595 7216, Fax 595 6564 ITEM PART NO. NUMBER DESCRIPTION REFERENCE/ZONE ASSEMBLY/QUANTITY DESIGNATOR 2021601-001 ASSEMBLY, METHANATOR, 120/240 1 2021601-AD ASSEMBLY DRAWING 2 2021606-001 3 2021604-001 4 UNIT -001 MEAS X REF EA COVER, METHANATOR ASSEMBLY 1 EA 1 EA 1531000-026 HEATER, BLOCK, METHANATOR O-RING,SILICONE RUBBER,76.0MM OD 2.5MM DIAMETER 1 EA 5 2021623-001 ASSEMBLY, METHANATOR BASE 1 EA 6 1312530-007 WASHER, M4, HELICAL SPRING LOCK, SST 4 EA 7 1312420-346 SCREW, M4X6, SOCKET HEAD CAP, SST 5 EA 8 2021603-001 INSULATION, METHANATOR, LOWER 1 EA 9 2021603-002 INSULATION, METHANATOR, CENTER 1 EA 10 2021603-003 INSULATION, METHANATOR, UPPER 1 EA REV ACTION DRAWN CHECKED APPROVED DATE PRODUCT LINE ANALYTICAL Siemens Applied Automation LEVEL 3 DESIGN DATE AA L9667 SIMONS SMITH KESSELH 02-3 PFALZER 02-03 DRAWN DATE AB D9785 SMITH SMITH KESSELH 02-4 SIMONS 02-03 AC D10371 WIDENER WIDENR COLLINS 02-10 SMITH PARTS LIST FOR ASSEMBLY, METHANATOR, 120/240 MAXUM II CHECKED 02-3 APPROVED KESSELHUTH 02-3 SCALE SIZE TYPE NONE A PL DRAWING NO. 2021601 REV AC SHEET 1 OF 2 ITEM PART NO. NUMBER DESCRIPTION REFERENCE/ZONE DESIGNATOR ASSEMBLY/QUANTITY UNIT -001 MEAS 11 2021262-002 PLATE, METHANATOR MOUNTING 1 EA 12 2021604-002 COVER, HEATER, BLOCK, METHANATOR 1 EA 13 1312413-036 SCREW,M4X10,FLAT HEAD SOCKET,SST 3 EA 14 2021172-005 COVER, DETECTOR, METHANATOR 1 EA 15 2021636-001 PIPE, MODIFIED, METHANATOR 1 EA 16 1317001-026 GROMMET, ID 13/16", GROOVE DIA. 15/16" 1 EA 17 2021607-001 CABLE, GROUND, METHANATOR, LONG 1 EA 18 2021607-002 CABLE, GROUND, METHANATOR, SHORT 1 EA 19 1684021-002 CABLE TIE,4",TEFZEL,HI TEMP, UV RESIST 2 EA 20 1621004-012 HEATER, 1” CARTRIDGE, 120V, FIREROD 2 EA 21 N80005 NUT,TRU-SEAL,1/2,STL 1 EA 22 F10900 CONDUIT,NUT,DRIVE 1/2 1 EA 23 1622001-020 RTD, PUSH-IN STYLE, 1” LONG, .188”OD 1 EA 24 T08800 TAPE,1/2" GLASS CLOTH AR MM 25 2021696-001 TAG, METHANATOR, CENELEC 1 EA 26 1371000-001 GREASE, FLUORINATED, KRYTOX, 240AC AR EA 27 2020184-001 TAG, METHANATOR, CATALYST WARNING 1 EA SCALE NONE SIZE A TYPE PL DRAWING NO. 2021601 REV AC SHEET 2 OF 2 Methanator Description The methantor is used with an FID when detection of CO and CO2 is required. Methanator Operation In the methanator CO and CO2 are catalytically reduced to methane under excess hydrogen, which can be detected in the FID: CO + 3 H2 CO2 + 4 H2 Ni → Ni → CH4 + H2O CH4 + 2 H2O Other areas of application are the reduction of formic acid and formaldehyde to CH4. This permits quantitative detection of small concentrations in the ppm range. HCOOH + 3 H2 HCOH + 2 H2 Ni → Ni → CH4 + 2 H2O CH4 + H2O If possible, the samples should not contain any halogenated or sulfurous components. Operational Note Hydrocarbons above C8 are partially decomposed through the catalyst. They appear with tailing and too small. The simultaneous detection of higher boiling components and CO/CO2 is therefore not possible. Hydration Reactor (Methanator) The hydration reactor consists of a stainless steel U pipe that is filled with a catalyst. A heating plate is plugged on the U pipe. Two heating cartridges and a Pt 100 temperature sensor regulate heating to 400 °C. The U pipe is installed in a base plate airtight. The gas inlets and gas outlets are configured as flame barriers. A protective cover is installed airtight over the base plate. The cover is insulated to prevent the surface temperature from exceeding 180 °C. In the ex-version the U pipe is encapsulated and pressure proof. The base plate contains a gas connector and exhaust nozzles for purge gas. The gas connector has a pipe, which extends into the purged shaft behind the installation chamber. This pipe is used to hold the connection lines for heating cartridges and temperature sensor. Purge gas flows from the purged shaft into the methanator housing through this pipe and prevents explosive gas from reaching the heater connections. ITEM PART NO. NUMBER 2021564-001 DESCRIPTION REFERENCE/ZONE 2021564-005 1 2021564 -A D ASSWMBLY DRAWING 2 2021171-001 3 2021564-002 2021564-003 2021564-004 -001 DESIGNATOR METHANATOR, INSTALLATION PACKAGE, NONE METHANATOR, INSTALLATION PACKAGE, AIR BATH OVEN, RIGHT POSITION METHANATOR, INSTALLATION PACKAGE, AIR BATH OVEN, LEFT POSITION METHANATOR, INSTALLATION PACKAGE, AIR BATH OVEN, BOTH POSITIONS METHANATOR, INSTALLATION PACKAGE, AIRLESS OVEN, RIGHT POSITION ASSEMBLY/QUANTITY -002 -003 UNIT -004 -005 MEAS X X X X X REF REF REF REF REF EA GASKET, DETECTOR 2 2 2 2 2 EA 2021172-001 COVER, DETECTOR W/O HOLES 2 1 1 - 1 EA 4 1312601-004 NUTS, M4 WITH LOCKWASHER 8 8 8 8 8 EA 5 2021215-001 PLATE, OVEN COVER, DETECTOR 2 1 1 - 1 EA 6 1312421-069 SCREW, M4 X 8 SOCKETM BUTTON HEAD CAP 8 8 8 8 8 EA 7 1312530-007 WASHER, M4, HELICAL SPRING LOCK, SST 8 8 8 8 8 EA 8 2021601-001 ASSEMBLY, METHANATOR, 120/240 - 1 1 2 1 EA 9 1212005-004 WIRE NUT, 22-24 GAUGE - 1 1 2 1 EA 10 T08500 TAPE,3/4” ELECTRICAL - AR AR AR AR AR REV ACTION AA L9877 DRAWN SIMONS CHECKED SMITH APPROVED KESSELH DATE 02-5 PRODUCT LINE ANALYTICAL DESIGN LEVEL SIMONS 02-04 DRAWN DATE SIMONS 02-04 CHECKED DATE SMITH 02-5 APPROVED DATE KESSELHUTH 02-5 Siemens Applied Automation 3 DATE PARTS LIST FOR METHANATOR, INSTALLATION PACKAGE MAXUM II SCALE NONE SIZE A TYPE PL DRAWING NO. 2021564 REV AA SHEET 1 OF 4 ITEM PART NO. NUMBER 11 2021700-001 DESCRIPTION REFERENCE/ZONE DESIGNATOR ASSEMBLY/QUANTITY -001 -002 -003 -004 -005 MEAS - 1 1 1 1 EA TAG, METHANATOR WARNING SCALE NONE SIZE A UNIT TYPE PL DRAWING NO. 2021564 REV AA SHEET 2 OF 4 ITEM PART NO. NUMBER DESCRIPTION REFERENCE/ZONE 2021564-007 1 2021564 -A D ASSWMBLY DRAWING 2 2021171-001 3 2021564-006 -006 DESIGNATOR METHANATOR, INSTALLATION PACKAGE, AIRLESS OVEN, LEFT POSITION METHANATOR, INSTALLATION PACKAGE, AIRLESS OVEN, BOTH POSITIONS ASSEMBLY/QUANTITY UNIT -007 MEAS X X REF REF EA GASKET, DETECTOR 2 2 EA 2021172-001 COVER, DETECTOR W/O HOLES 1 - EA 4 1312601-004 NUTS, M4 WITH LOCKWASHER 8 8 EA 5 2021215-001 PLATE, OVEN COVER, DETECTOR 1 0 EA 6 1312421-069 SCREW, M4 X 8 SOCKETM BUTTON HEAD CAP 8 8 EA 7 1312530-007 WASHER, M4, HELICAL SPRING LOCK, SST 8 8 EA 8 2021601-001 ASSEMBLY, METHANATOR, 120/240 1 2 EA 9 1212005-004 WIRE NUT, 22-24 GAUGE 1 2 EA AR AR AR 10 T08500 REV ACTION TAPE,3/4” ELECTRICAL DRAWN CHECKED APPROVED DATE PRODUCT LINE Siemens Applied Automation LEVEL DESIGN DATE DRAWN DATE CHECKED DATE APPROVED DATE PARTS LIST FOR SCALE NONE SIZE A TYPE PL DRAWING NO. 2021564 REV AA SHEET 3 OF 4 ITEM PART NO. NUMBER 11 2021700-001 DESCRIPTION REFERENCE/ZONE DESIGNATOR ASSEMBLY/QUANTITY -006 -007 MEAS 1 1 EA TAG, METHANATOR WARNING SCALE NONE SIZE A UNIT TYPE PL DRAWING NO. 2021564 REV AA SHEET 4 OF 4