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Fundamental Guidelines for the Successful Design of a Process Analyzer System.

Revised October 2004

David Lewko - CSAT

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Agenda

• Definitions• Design Requirements• Available Resources• Bill of Materials • Hours / Schedule• System Design Requirements• Factory / Site Acceptance Testing • Documentation

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Definitions

• On-Line Process Analyzer• Process Analyzer System• Analyte

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On-Line Process Analyzer

• A Process Analyzer provides an output signal representing either the concentration of a specific component or the physical properties of a process stream.

• An On-Line Process Analyzer is designed to operate continuously in an unattended fashion.

• Analytical measurements may be made of conventional process streams, the atmosphere, stack emissions or discharge lines to open streams or rivers.

• The term On-Line Analyzer is not associated with either lab instruments or those used in manual survey situations such as a RATA Test.

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Process Analyzer System

An On-Line Process Analyzer System consists of:• Process Analyzer• Sample Extraction Probe (if required)• Sample Delivery / Return Lines (if required)• Sample Conditioning System (if required)• Calibration / Carrier Gas Cylinders (if required)• Calibration System (if required)• Shelter or Panel (if required)• Sample Recovery system (if required)• System Documentation.

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Analyte

An analyte is the concentration of a specific component in a process stream, or the physical properties of the process stream. For example:

Concentration of a specific component in a process stream - The maximum allowable of H2S in sales gas is 16 ppmv.

Physical Property of a process stream - One of the grades of Motor Gasoline has an Octane Rating of 97.

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Design Requirements

We have all seen the posters in design offices throughout North America

Does it Work

Is it Safe

Does it Meet Scope

I would suggest that these posters do not address the full requirements

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Design Requirements (continued)

• Does it Work (and is the design practical)• Is it Safe (in both normal operation and during

periods of routine maintenance)• Does it Meet Scope (including meeting the project

schedule, the project budget, and all applicable regulations and specifications)

• Can the system be installed and commissioned with a minimum of Field Requests for Information and no Technical Deviations.

• After a period of a few years, will the system still be in operation and not have been re-designed by the end user.

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Available Resources

• The RE has numerous resources available throughout the completion of an analyzer system.

• Available resources take on many forms and may be internal to the company or external.

• The number of resources utilized may vary depending on the complexity of the process analyzer system.

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Analyzer System Design

Client Manufacturer/ Vendor

User Reports

PastExperience

Governing Codes

Standards &Recommended

Practices

Piping Process

CivilStructural

Electrical I & C

TechnicalPresentations,

Internet & Journals

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Available Resources (continued)

Process Department

• The RE will have to work with the Process Department to identify the types of Process Analyzers required for the project.

• The RE will have to work with the Process Department to establish P&ID symbology for the Process Analyzer Systems.

• The RE will have to work with the Process Department to identify all of the information needed for the Instrument Data Sheets.

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Civil Department

• The RE will have to work with the Civil Department to identify locations Analyzer Shelters and / or Analyzer Panels

• The RE will be responsible for coordinating with both the Civil Department and the Vendor for the anchoring systems

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Piping Department

• The RE will have to reference the project piping specifications for utility piping with in an analyzer shelter (ie Instrument Air Headers, Pressure Relief Headers, etc).

• The RE will be responsible for having the 3D coordinates for piping terminations from the shelter identified on the vendor drawings.

• The RE will have reference piping specifications when identifying test procedures for utility piping systems within the shelter.

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Electrical Department • The RE will have to reference electrical specifications when

developing the specification for analyzer shelters and / or analyzer panels. This includes voltages, preferred manufacturers, etc.

• The RE will be required to work with the Electrical Department for verification of the area classification within the Analyzer Shelter as well as within Sample Conditioning Enclosures

• The RE will be responsible for providing the Electrical Department with electrical loads (including both normal operating and start-up currents) for all analyzer systems.

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I&C Department

• The RE will be responsible for ensuring that all process analyzers systems are entered correctly in the Instrument Index.

• The RE will be required to work with the wiring group to develop any non-typical loop templates for the process analyzers, or components in the Sample Conditioning System(s).

• The RE will be responsible for ensuring the required information is included in the Construction Work Packages.

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Governing Codes, Standards and Recommended Practices

• The RE will be responsible for staying current with all governing codes, standards or recommended practices that pertain to the design of Process Analyzer Systems.

• The RE will be responsible for identifying discrepancies between various governing codes, standards or recommended practices when preparing the technical requisition for process analyzer systems.

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Technical Presentations, Internet and Journals• The RE will be responsible for staying current with

advancements in analytical technology.• The Analysis Division spring symposium is an excellent

venue when it comes to staying current with modern developments. In addition to the technical presentations, it is an excellent venue to develop a network of people in the analytical community.

• With the ever expanding Internet, the amount of current information can be overwhelming. The challenge is to keep track of the useful URLs.

• Lastly, technical journals still serve as a resource in staying current with new developments in analytical instrumentation.

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The Client

• Rule # 1 - The Client can prove to be the most valuable resource available to the RE for the duration of the project.

• Rule # 2 – See Rule # 1.

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User Reports

• User Reports for the performance of a given analyzer can be a valuable tool for the technical evaluation.

• Care must exercised to ensure the existing users application is similar in nature.

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Past Experience

• In many cases the RE will be able to draw on past experience when starting a new project.

• These past experiences may include complex sample conditioning system layouts, performance of given process analyzers, solutions developed for complex problems or lessons learned.

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Manufacturers / Vendors

• Manufacturers and / or their assigned representatives can be a useful resource in the beginning phases of a project when identifying the types of analyzers.

• It must be recognized that not all information received from the vendor community can be accepted as ……………...

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Bill of Materials

• In many cases the Bill of Materials is developed from the Process Flow Diagrams (PFDs).

• For the purposes of this presentation I am going to use the discharge from a Sour Water Stripper as an example.

• The analytes of interest are pH, Total Amonnia and Total Hydrogen Sulphide.

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Bill of Materials (continued)

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Bill of Materials (continued)

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Hours / Schedule

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Instrument Index

• Once the Bill of Materials has been completed, the Instrument Index can be populated.

• The Instrument Index can be used for the generation of reports in the project templates as well as preliminary Instrument Data Sheets.

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Shelter / Panel Locations

• The P&IDs are used as a reference to initially identify the locations of the sample extraction points on the Plot Plan.

• This information is used to identify the initial locations for shelters and / or panels on the process plot plan.

• The locations of the shelters and / or panels can then be generated in the 3D PDS Model.

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Shelter / Panel Locations

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Analyzer Shelter and Panel Design

The RE will be responsible for the following items in the detail design phase of the project:

• Size and GA of the shelters and panels• Final locations on the plot plan• Sample conditioning and recovery requirements• Compliance with area classification and T Ratings• Environmental protection • HVAC requirements• Fire and gas detection• Junction box requirements• Documentation.

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General Arrangement and Size

• The spacing of analyzers must allow adequate clearance on all three sides for two technicians

• In many cases manufacturers publish minimum clearances for service and calibration of the equipment.

• Service and egress routes have to be maintained when establishing general arrangements.

• Service access for equipment such as replacement carrier gas cylinders, filters, consumable components, etc.

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Location of Shelters and Panels

• The P&IDs are used as a reference to initially identify locations of the sample extraction points on the Plot Plan.

• This information is used to identify the initial locations for shelters and / or panels on the process plot plan.

• The process plot plan and the 3D PDS Model are used for the final equipment locations

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Sample Conditioning and Recovery Requirements• In cases involving a single analyzer, the RE may be best off

to have the analyzer manufacturer design and supply the sample conditioning system.

• In cases involving multiple suppliers of process analyzers, it may be beneficial to design a single sample conditioning system when a single sample conditioning system addresses the requirements of multiple analyzers.

• In cases involving liquid samples, a Sample Recovery System is used to return excess sample back to the process.

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Electrical Classification

As a general rule:• The area classification on the interior of a well ventilated

shelter will be the same as the surrounding area that the shelter is installed in.

• The shelter will be ventilated in accordance with API and NFPA guidelines. In some cases client specifications may be more stringent than either API of NFPA.

• The interior of non-ventilated sample conditioning enclosures will be Zone 1.

The Project Electrical Engineer has the final say on all electrical area classification issues.

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Environmental Protection

• In many cases the process analyzers will require environmental protection.

• In northern climates, this will require heating of the shelter, sample conditioning enclosure and sample transport tubing

• In tropical climates, this may take the form of a rain guard.

• In hot desert climates, the client may specify redundant air conditioners in the shelter.

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Environmental Protection (continued)

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Environmental Protection (continued)

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HVAC Requirements

• In Canada analyzer shelters are normally supplied with a self contained HVAC unit which is sized to provide 6 air changes per hour and maintain an interior temperature of 20 Deg C, +/- 2 Deg.

• The Mechanical Engineer will be the primary resource when specifying the HVAC unit.

• In rare cases the RE will be asked to provide calculations to determine the LEL within the shelter in the event of a leak in the carrier gas supply.

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HVAC Requirements

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Fire and Gas Requirements

• Analyzer shelters are typically provided with Ambient Gas Detection in accordance with the overall plant wide Fire and Gas Philosophy.

• Depending on the actual end user, the shelter may also be provided with Fire Detection.

• In rare cases, detection of Oxygen Depletion may also be included in the design of the shelter.

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Fire and Gas Requirements (continued)

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Testing Requirements

Depending on the project, testing can take on several forms

• For complex GC networks, a fully functional Factory Acceptance Test may be preformed at the factory.

• For large analyzer systems, a fully functional Factory Acceptance Test may be preformed at the integrators facility.

• For proven analyzers, testing may be configured to concentrate on the integration of the analyzer(s).

• In some cases a fully functional Factory Acceptance Test may be preformed after installation at site.

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Testing Documentation

The index for a detailed test plan would contain the following chapters:• Scope of Supply from the Technical Requisition• Testing procedures for the analyzers and all associated

equipment.• Action Log for all discrepancies• Instrument Loop diagrams• Installation Details • Instrument Data Sheets• As-built Drawings

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Documentation

• In the case of complex analyzer systems, the vendor drawing package will be quite complex effecting all disciplines of the design team.

• The drawing package may contain a large number of drawings, depending the complexity of the system.

• In the case of large complex systems, it is beneficial to conduct the drawing review in a board room type environment rather than the conventional squad check table format.

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