ABB Hydrogen Analyzer Systems

ABB Automation

Hydrogen Analyzer Systems

Unrivaled Safety and Technical Expertisefrom the #1 Name in Hydrogen Measurement

instrumentation

understanding measurement analysis control integration optimization

World leader in hydrogen analysis

Triple range analyzers

Fail-safe design

Fully certified for intrinsic safety

Simple to retrofit

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Eighty years of experience, unparalleled safetyand innovative design has positioned ABBAutomation as the world leader in hydrogenanalysis. Our expertise in designing andmanufacturing thermal conductivity analyzersfor hydrogen cooled generators enables us tobring the most safe, the most flexible and themost cost effective solution to market. Like theentire family of ABB Automation products, therange is manufactured to the highest level ofquality, and is backed by ABB’s world-classservice and support organization.

Superior Technology, Quality and

Reliability from the World Leader

in Hydrogen Measurement

Importance of Hydrogen Purity

To increase plant profitability and maintainfoolproof conditions against explosions,turbine generators must perform with optimalefficiency. Efficiency is linked directly tohydrogen purity because a drop in the puritycauses windage losses that subsequentlyreduce generator efficiency. For this reason,continuous, highly accurate hydrogenmonitoring is vital for generator efficiency,for generator safety and for lowering operatingcosts per megawatt.

Cost of Decreased Hydrogen Purity

Data based on typical power station operating conditions.

% Hydrogen Purity

Fin

ancia

l Loss

, $U

S/d

ay

4,500

4,000

3,500

3,000

2,500

2,000

1,500

1,000

500

01 0 0 9 9 9 8 9 7 9 6 9 5 9 4 9 3 9 2 9 1

800 MW Unit

400 MW Unit

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Turbogenerator Application

Hydrogen gas is an ideal coolant for today’shigh capacity turbine generators. Hydrogen’sthermal conductivity rate, seven times that ofair, gives the gas excellent heat transferringproperties. Another benefit comes from itsnatural low-density state, which greatly promotescooling efficiency and helps to optimize generatorperformance.

ABB’s complete system for hydrogen measure-ment involves a total of five products. A displayand control monitor, which is incorporated inthe turbogenerator purge control cubicle,indicates all measurement results with fail-safereliability. Two thermal conductivity analyzersand two power supply units complete thesystem. While the power units must be installedin a safe area, the current they output istransmitted to the hazardous area, where thethermal conductivity analyzers – the heart ofthe system – are located.

Operating Principle

ABB’s thermal conductivity analyzers continuallymeasure hydrogen purity during normal turbineoperations. They also provide the reliable, safemeasurement of hydrogen in carbon dioxideduring the initial purge and the measurementof carbon dioxide in air during the final purge.Hydrogen can be highly explosive whenmixed with air, so this function is essential formaintaining ranges that are within acceptablesafety limits. It also helps you to achieveoptimum hydrogen purity levels and tomaximize operational efficiency.

The thermal conductivity analyzers operate onthe principle of a Wheatstone bridge. A pairof glass coated, platinum filaments – one pairfor reference and one pair for measurement –are located on each arm of the bridge. Aconstant current is passed through the bridgenetwork and in doing so, any differencebetween the thermal conductivity rates of thereference gas and the measurement gas willcause an imbalance of the bridge. This im-balance signals the difference in the thermalconductivity of the two gases, thus identifyingeach gas and how much of it is present in themixture. The display unit can be calibrateddirectly in terms of the percentage of one gaswith another gas.

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Customizable Hydrogen Panels

ABB Automation offers flexible solutions tobest meet your operational needs. For example,the hydrogen analysis panel can be configuredas a single hydrogen in air measurement, witha separate panel for the carbon dioxide referencee.g., hydrogen in carbon monoxide and air incarbon monoxide. Or, the hydrogen analysispanel can be configured with all three measure-ments on a single panel, which is ideal forapplications that require triple range analysis.

ABB addresses the most critical safety issueswith our optional redundant systems. In usingthis type of panel configuration, you will alwayshave a backup for the crucial measurement ofthe three gas ranges.

Here are the hydrogen panel options in detail:

System A is the most cost effective solution.It consists of one measurement panel thatprovides all three gas ranges. This indicateshydrogen purity 100%–85% or 85%–100%(fail-safe) hydrogen in air, as well as 0%–100% hydrogen in carbon dioxide and0%–100% air in carbon dioxide.

• Triple range analyzer

• Retransmission output for eachmeasurement

• LCD display for easy reading

System B is ABB’s traditional offering, andserves as the upgrade system for existinggenerators and new installations. This config-uration employs one panel to measure 100%-85%, 85%-100% (fail-safe) hydrogen in air andis accompanied by a dual range analyzer panelfor 0%-100% hydrogen in carbon dioxide and0%-100% air in carbon dioxide.

• Low maintenance andinstallation costs

• Easy to retrofit

• 4 mA – 20 mA display outputenables data transfer to DCSor central control room

System C is targeted to applications wherereadings are so critical that they require abackup system. It provides the same config-uration of the triple range thermal conductivityanalyzer panel (System A), with the extrainsurance of a duplicate panel for backup.

• Redundant system

• Fail-safe design

• Fully certified

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H2 in air100% to 85% or85% to 100%H2 and air in CO20% to 100%

Analyzer Panel

Connect to110/120V or200/220/240V50/60 Hz


Lower indicator:One retransmission perposition on selectorswitch + 2 relays each

Power Supply UnitModel 4234 issue 5

Upper indicator:Two relaysOne retransmission

Zener BarrierUnits

Hazardous Area Safe Area

H2 in air100% to 85% or85% to 100%

Analyzer Panel

0 to 100% H2 in CO2

0 to 100% air in CO2




Power Supply UnitsModel 4234 issue 5


Zener BarrierUnits


Analyzer Panel

Analyzer Panel




Power Supply UnitsModel 4234 issue 5


Zener BarrierUnits


Analyzer Panel

85% to 100% H2 in air0 to 100% H2 in CO2


85% to 100% H2 in air0 to 100% H2 in CO2


System A

System C

System B

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As operational demands continue to increase,the one area that cannot be compromised issafety. Safety will always be a paramountconcern for turbogenerator operations, due topotential explosions caused by air mixing withhydrogen. The ABB hydrogen analysis systemeases the stress of working in hazardous environ-ments by providing continuous, reliablemonitoring of hydrogen purity without fail.

Should your input signals become opencircuited, the system’s display and controlmonitor will automatically protect you fromunsafe indications. In such cases, two-stepalarms will immediately alert the operatorto failing hydrogen purity or to faulty purgesequences, and a device will drive theinstrument downscale – to the low purity,purge zero end of the scale – to provide theappropriate warning and ensure urgentcorrective action by the operator.

• Continuous monitoring of hydrogen purity

• Certified for intrinsic safety

• Two-step alarms for indicatingimmediate danger

• Optional independent redundant systemsfor enhanced measurement security

Uncompromising Safety

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Hydrogen Purity Selector Chart

System Thermal Auxiliary Services SystemType Conductivity Panels Equipment Required Characteristics

A 6540 203K panel 4234 power supply 115/230 VAC 4-20 mA output for each range100%-85% or 85%-100% for each panel 600T pressure two relay alarm contactshydrogen in air, 0%-100% 6553/6131/201/102 transmitter, intrinsic safety approvalhydrogen in carbon dioxide display unit sample filters Class 1, Div. 1, Group Band air in carbon dioxidealso available for 147psig

B 6540 203K panel 4234 power supply 115/230 VAC 4-20 mA output for each range100%-85% or 85%-100% for each panel 600T pressure two relay alarm contactshydrogen in air, 6540 203K 6553/6131/201/102 transmitter, intrinsic safety approvalpanel 0%-100% hydrogen in display unit sample filters Class 1, Div. 1, Group Bcarbon dioxide and 0%-100%air in carbon dioxide bothavailable in 147 psig

C 6540 203K panel 100%-85% 4234 power supply 115/230 VAC 4-20 mA output for each rangeor 85%-100% hydrogen in air, for each panel 600T pressure two relay alarm contacts0%-100% hydrogen in carbon 6553/6131/201/102 transmitter, intrinsic safety approvaldioxide and 0%-100% air in display unit sample filters Class 1, Div. 1, Group Bcarbon dioxide6540 203K panel 100%-85%or 85%-100% hydrogen in air,6540 203K panel 0%-100%hydrogen in carbon dioxide and0%-100% air in carbon dioxideboth available in 147 psig

3BUS095002R0001Copyright © 2000 by ABB Automation Inc. All rights to trademarks reside with their respective owners.Specifications subject to change without notice. Pictures, schematics and other graphics contained herein are published for illustration purposes only and donot represent product configurations or functionality. User documentation accompanying the product is the exclusive source for functionality descriptions.

ABB Instrumentation Ltd.Oldends LaneStonehouse, Glos.England GL 10 3TATelephone: +44 (0) 1453 826 661Telefax: +44 (0) 1453 827 856

ABB Automation Inc.Instrumentation Division125 East County Line RoadWarminster, PA 18974 USATelephone: +1 215-674-6000Telefax: +1 215-674-7183

For additional information, visit uson the Internet at www.abb.com

Documents

ABB Hydrogen Analyzer Systems