B.3.10 Analysers Spec [PDF]

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STANDARD SPECIFICATION FOR PROCESS STREAM ANALYSERS AND CHROMATOGRAPHS

DOCUMENT NO : 44-LK-5100-00/J.02/0013-A4

Rev No.

A

Issue Date

12.08.08

Pages

24

Rev Description

Issued for Comments / Approval

Prepared

Checked

Approved

By

By

By

RCK

GDR

BSP

JACOBS ENGINEERING INDIA PRIVATE LIMITED

DOCUMENT NO : 44-LK-5100-00/J.02/0013-A4 STANDARD SPECIFICATION FOR PROCESS STREAM ANALYSERS AND CHROMATOGRAPHS

Date : 12.08.08 Page 2 of 24 Revision No. : A

TABLE OF CONTENTS 1.0

PURPOSE

2.0

SCOPE

3.0

TECHNICAL REQUIREMENTS

3.1 3.2 3.3 3.4 3.5 3.6

DEFINITIONS GENERAL SPECIFICATIONS for ANALYSERS AND CHROMATOGRAPHS GENERAL SAMPLING SYSTEM SPECIFIC ANALYSER GUIDELINES CALIBRATION ADDITIONAL REQUIREMENTS FOR CHROMATOGRAPHS

4.0 5.0 6.0 7.0 8.0

ANALYZER SHELTER TESTING AND INSPECTION DOCUMENTATION WARRANTY CONTRACT AND SERVICES REFERENCE STANDARDS

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_________________________________________________________________________ DOCUMENT NO :44-LK-5100-00/J.02/0013-A4 STANDARD SPECIFICATION FOR PROCESS STREAM ANALYSERS AND CHROMATOGRAPHS

1.0

Date : 12.08.08 Page 3 of 24 Revision No. : A

PURPOSE The purpose of this specification is to define the minimum requirements of design and manufacture of process stream analysers, gas chromatographs, their associated sample conditioning equipment and gas detection system.

2.0

SCOPE The scope of work shall include design, manufacture, testing and supply of process stream analysers, gas chromatographs, their associated sample conditioning equipment and complete gas detection system including all detectors, monitors, control panel duly wired and any other hardware as necessary. The inspection requirements shall be as per the inspection plan.

3.0

TECHNICAL REQUIREMENTS

3.1

DEFINITIONS

3.1.1

Analyser - is defined as a specialised instrument for measuring or inferring physical or chemical properties, or chemical composition, of gases, liquids, or solids in process streams.

3.1.2

Sample conditioning equipment - is defined as a combination of modules installed upstream of an analyser used to prepare process samples for analysis. Examples of commonly used modules include filters, vaporisers, pressure regulators and separators.

3.1.3

Repeatability - is defined as the closeness with which an analyser repeats indications when measuring identical values of the variable under the same conditions.

3.1.4

Sensitivity - is defined as the smallest change in a variable capable of causing a measurable corresponding change in signal output.

3.1.5

Chromatograph: - A stand alone, unit architecture based microprocessor controlled instrument consisting of chromatograph proper, sample conditioning system and programmer which is capable of working and generating hardwired and serial outputs without the aid of any external device.

3.1.6

Programmer :- A microprocessor based device which is a part of chromatograph and controls the overall functioning of the system and also provides hardwired analogy and serial outputs.

3.2

GENERAL SPECIFICATIONS for ANALYSERS AND CHROMATOGRAPHS

3.2.1

In general analyser and sampling systems shall be designed and constructed in accordance with API-MPMS (Relevant portions). Analysers shall be suitable for outdoor installation and the specified environment. Vendor shall not offer any prototype instruments in his bid. All instruments offered should have been proven in refinery or petrochemical plants before bidding.

3.2.2

As a rule, no single analyser (detection system ) shall be used for measurement of more than one component except chromatographs which can be multi stream multi component

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DOCUMENT NO : 44-LK-5100-00/J.02/0013-A4 STANDARD SPECIFICATION FOR PROCESS STREAM ANALYSERS AND CHROMATOGRAPHS

Date : 12.08.08 Page 4 of 24 Revision No. : A

type based on requirement. Process Stream sampling shall be continuous. As a minimum, all analysers shall provide one 4-20mA signal along with 2 potential free contacts to the control system. In addition to the above, Chromatographs and IR analysers shall be provided with serial communication port, unless stated otherwise. 3.2.3

Analysers shall meet Zone 1 requirements unless the analyser is located in a nonhazardous area and the composition or amount of the sample inside the analyser is insufficient to produce an explosive or ignitable mixture in the event of component failure or leakage. Equipment associated with the analyser operation, located within an analyser shelter, shall meet at least Zone 2 requirements. Approved analysers and equipment which are required for hazardous areas shall be labelled, listed or certified by an internationally recognised testing organisation such as Underwriters Laboratory (U.S.A.), BASEEFA (U.K.) OR P.T.B. (Germany). Where such equipment is not available, its design shall conform to standards of a nationally recognised testing organisation. Purging of cabinets, analyser systems etc shall be avoided as far as possible. Where there is no other option but purging to meet area classification, purging shall be carried out as per NFPA-496 “ Purged Enclosures for Electrical equipment”

3.2.4

Analysers shall operate within specification at ±10% of the specified A.C power supply voltage and ± 2Hz of specified frequency. The analyzer power supply shall be provided from UPS.

3.2.5

Unless otherwise specified material of all components wetted by sample shall be ANSI 316 SS materials of construction and all wetted part components shall be chosen to prevent reaction of materials with the sample, absorption of components from the sample and entrance of contaminants through osmosis or diffusion.

3.2.6

Repeatability shall be ± 1% of span or better and Sensitivity shall be ± ½% of span.

3.2.7

Analyser enclosures and accessories shall be suitable for the specified electrical area classification. Unless otherwise specified, the enclosures shall be to the following standards :- Weather proof housing IP 55 as per IEC-60529 / IS-2147 - Flame proof housing Flameproof Ex (d) as per IEC-60079 / IS-2148 (Flameproof equipment shall also be made weatherproof) - Intrinsically safe version of analysers shall be as per following standards :Intrinsically safe BS 5501 / CENELEC EN 50020. All such analysers shall also be weatherproof to IP 55 as per IEC-60079 / IS-2147. The intrinsically safe and explosion proof equipment shall be certified by statutory bodies Like BASEEFA, FM, PTB, CMRI, etc.

3.2.8

All interconnecting wiring shall be colour coded / numbered and terminal blocks clearly identified.

3.2.9

The design of analyser system shall be in compliance with the electromagnetic compatibility requirements as per IEC-60801.

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Date : 12.08.08 Page 5 of 24 Revision No. : A

3.3

GENERAL SAMPLING SYSTEM

3.3.1

As a rule, separate sampling systems shall be provided for detecting each component unless stated otherwise. The sampling system shall be furnished with all the necessary equipment and accessories to condition and regulate the sample so as to supply the analyser with a continuously representative and measurable sample.

3.3.2

The sampling system shall be engineered, designed, fabricated and furnished completely assembled as an integral part of the analyser or as a separate package. The sampling system shall be designed on the basis of the utilities available as indicated in the job specifications.The analyser Vendor shall provide a completely fabricated sample conditioning system.

3.3.3

Each sampling system component shall be capable of being removed without disassembling the entire system.

3.3.4

If a separate sampling system is furnished, it shall be designed for easy integration with the analyser in the field.

3.3.5

Sampling system design shall be such that the sample drawn for analysis is truly representative of the process stream. Extra care shall be exercised in the selection of the various components forming the sampling system. Minimum material of construction for the sample system components shall be SS 316.

3.3.6

Sampling system shall be designed to move the sample from the process to the analyser proper in the shortest possible time. Transportation time for the sample from the process tapping point upto the sampling system shall not exceed 30% of the cycle time specified for the chromatograph. Sample tube material shall be selected based on process fluid requirements and tube size shall be recommended by vendor to suit process condition and avoid possible plugging. Any heat tracing requirement of sample tubing such as condensible process vapour shall be fulfilled using appropriate tracing with temperature control. No sample shall be vented to atmosphere unless specifically indicated otherwise. Sample disposal scheme shall be as per P&ID or agreed upon before implementation.

3.3.7

Sampling system shall consist of one or more of the following components as required by the service conditions: filters (coarse and fine) pressure regulators, relief valves, flow indicators, flow controllers, temperature indicators, scrubbers, heaters, coolers, dryers, sample probes, sample pumps, aspirators, etc. any additional equipment required shall be included by bidder. Vendor shall provide the facility of Auto calibration using solenoid valves unless stated otherwise.

3.3.8

Filters shall be always dual and it shall be possible to remove and replace one of the filters without upsetting the operation of the analyser. Pressure reduction where required shall be provided with a safety valve downstream. Variable area flowmeters shall be provided for Fast Loops.

3.3.9

The sampling system, analyser, etc. shall be supplied pre-mounted on a self-standing panel in general. The panel shall have holes to anchor it to the ground with anchor bolts.

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DOCUMENT NO : 44-LK-5100-00/J.02/0013-A4 STANDARD SPECIFICATION FOR PROCESS STREAM ANALYSERS AND CHROMATOGRAPHS

Date : 12.08.08 Page 6 of 24 Revision No. : A

The panel shall be weatherproof to IP 66 as a minimum. All components in contact with the sample shall be stainless steel unless otherwise specified 3.3.10

Process sample return point, if needed and utilities as required will be made available near the analyser at pressure and temperature conditions specified in the data sheet for each analyser as single point supply and return. In general, all the offered items are to comply with maximum pressure and temperature data specified. Multi-point distribution of utilities and process sample, as needed, is to be arranged by bidder following good engineering practices.

3.3.11

Consumables / accessories such as Calibration cylinders, Gas blending cylinders, Fuel gas cylinders etc. shall be supplied along with the analyser system keeping in mind the requirement for Start-up, commissioning and 1 year’s normal operation. Calibration gases shall be furnished with testing and validity certificates.Cylinders shall be stored external to the analyser shelter / cabinet with suitable mounting accessories for the same. Cylinders shall be supplied in 2 sets such that at any point of time, 1 set is in use and the other is for storage / refilling.

3.3.12

The sampling system shall contain at least one wire mesh strainer of US standard sieve mesh size 100 or finer. Where purchaser’s data sheets indicates greater possibilities of plugging, vendor shall provide more filters / separators as required. Where purchaser’s data sheets indicate possibilities of polymer formation of presence of excess polymers, vendor shall offer suitable design features to minimize plugging because of polymer residue.

3.3.13

Wherever the process stream pressure is low, vendor shall provide / advise the purchaser on use of aspirators or sample pumps. Vendor shall also indicate the utility requirements (e.g. Water or air) for such device. Sampling system shall include provision for connection of calibration standard.

3.3.14

For multi stream chromatographs separate sample handling sub-assembly for each Stream shall be provided with stream selecting valves shall be located as close as possible to the analyser to minimize connecting tubing length and possibility of crosscontamination of samples. Stream selecting valves shall have bubble tight shut off and shall be fail closed so as to block the samples from analyser. Multi stream sample system shall consider the use of double block with atmospheric pressure configuration with scavenging to prevent cross-contamination when vendor’s experience for the particular application involved, demands this precaution.

3.3.15

When fast loop is specified, vendor shall be provide flowmeters for sample bypass flow. Sample return line to process shall be provided with isolation valves and check valves. In case of multi stream gas chromatographs, separate fast loop return lines shall be provided for each stream. Return pressure shall be higher than the pressure of the process destination point specified by purchaser.

3.3.16

All Analyzers shall be provided with Failure Alarms to alert the plant operator.

3.3.17

Interconnecting Wiring And Terminals

3.3.17.1

Interconnecting wiring shall be either colour coded or numbered. All terminal blocks shall be clearly identified, and all individual terminals shall be clearly marked.

3.3.17.2

The Vendor shall specify requirements for separation or shielding of power and signal lines, or both.

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_________________________________________________________________________ DOCUMENT NO :44-LK-5100-00/J.02/0013-A4 STANDARD SPECIFICATION FOR PROCESS STREAM ANALYSERS AND CHROMATOGRAPHS

3.4

Date : 12.08.08 Page 7 of 24 Revision No. : A

SPECIFIC ANALYSER GUIDELINES Type of analyser selected shall be as per P&ID and process data sheets attached in the Process Package. Certain minimum requirement of specific analyser types are indicated as below :-

3.4.1

Infra Red / Ultra Violet Analysers

3.4.1.1

The analyser system shall consist of the following : • Sampling system • Detector, amplifier and transmitting electronics • Integral indicator with 0-100 percent linear reading

3.4.1.2

Analysers shall be of the non-dispersive type.

3.4.1.3

Special filters shall be provided to minimise the interference of background components, which are of least interest in the process stream. Windows and cells used in the unit shall be suitable for the specified service.

3.4.1.4

The following performance characteristics shall be met, as a minimum, unless otherwise specified: Accuracy Repeatability Noise Span and zero drift Speed of response

: : : : :

± 2% of full scale ± 1% of full scale Less than 1% of full scale ± 1% full scale per 24 hours Less than 5 seconds for 90% of final reading

3.4.2

Density / Specific Gravity Analyser

3.4.2.1

The analyser system shall consist of the following : • • •

Sampling system Detector, amplifier, transmitter electronics Converter

However, bidder may offer direct probe type detector without a sampling system if the service conditions permit. In such a case, design shall ensure on-line removal of detector without any process upset. 3.4.2.2

The sensing portion shall not employ any mechanical moving parts.

3.4.2.3

The measurement of density of liquids shall not be affected by variation in pressure, flow rate or viscosity of the process fluid. The density / specific gravity sensor shall have built in temperature compensation.

3.4.2.4

The converter shall be a microprocessor based programmable unit and shall provide isolated analog current output as specified in the data sheet.

3.4.2.5

The following performance characteristics shall be met, as a minimum:

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DOCUMENT NO : 44-LK-5100-00/J.02/0013-A4 STANDARD SPECIFICATION FOR PROCESS STREAM ANALYSERS AND CHROMATOGRAPHS

Accuracy Repeatability

: :

± 0.1% of span ± 0.01% of span

3.4.3

Moisture Analyser

3.4.3.1

The analyser system shall consist of the following : • • • •

3.4.3.2

Date : 12.08.08 Page 8 of 24 Revision No. : A

Probe assembly or cell Sampling system Transmitter electronics Analyser control unit

Probe Assembly -

The probe when mounted inline shall not be damaged by severe shock and vibration conditions.

-

Each probe shall be supplied as calibrated and shall be provided with its own calibration curve.

3.4.3.3

Analyser control unit

3.4.3.3.1

The control unit shall be solid state programmable type. The electronics shall be self calibrating.

3.4.3.3.2

The control unit shall provide the following : • Isolated analog current output signal • A built in dual high and low set point alarm with SPDT contacts rated 5 amp at 110V AC. • Direct read-out of ambient temperature. • Automatic sequencer of sequential readings of same points in multistream analysis.

3.4.3.3.3

The following performance characteristics shall be met as a minimum. • • •

Accuracy Repeatability Sensitivity

: : :

3.4.4

Oxygen Analyser

3.4.4.1

Paramagnetic Type

3.4.4.1.1

The analyser shall consist of • •

± 1% of full scale ± 0.5% of full scale 0.5 parts per million by volume.

Sampling system Sensor, analyser electronics and transmitter unit with local readout

3.4.4.1.2

The analysis shall not be affected by changes in background gas composition.

3.4.4.1.3

It shall be possible to change the range of measurement with the help of a selector switch to be provided on the analyser front panel.

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Date : 12.08.08 Page 9 of 24 Revision No. : A

3.4.4.1.4

The measurement shall not be affected by changes in sample pressure, flowrate, sample vent pressure and ambient temperature.

3.4.4.1.5

Analyser failure alarm shall be provided.

3.4.4.1.6

Paramagnetic analyser shall meet the following performance characteristics as a minimum Accuracy Repeatability Response time

: : :

± 1% of full scale ± 0.005% of oxygen 6 seconds for 90% response

3.4.4.2

Electrochemical Type

3.4.4.2.1

The analyser system shall consist of the following : • •

Sampling system Sensor, analyser electronics and transmitter unit with local readout

3.4.4.2.2

Zirconia cell sensor shall be complete with sample and bypass flowmeters and flow control valve and shall be resistant to thermal and mechanical shocks.

3.4.4.2.3

Aqueous type electrochemical cell shall be non-depleting type and shall be drift free. The cell shall be capable of recovering from exposure to high concentration of oxygen on its own.

3.4.4.2.4

It shall be possible to change the range of measurement with the help of a selector switch on the analyser front panel.

3.4.4.2.5

The following performance characteristics shall be met as a minimum : Accuracy Repeatability Response time

: : :

± 2% of full scale ± 2% of full scale Less than 15 seconds for 90% response

3.4.5

Flue gas oxygen analyser (zirconia cells type)

3.4.5.1

The analyser shall consist of the following: • • • •

3.4.5.2

Shield assembly and adapter plate Probe assembly Control unit Reference gas control

Shield Assembly • •

The shield assembly shall be attached to the stack or duct through the adapter plate and shall provide mechanical support and thermal insulation for the probe. All the accessories like adapter plate, gaskets, bolts required for mounting probe and shield assemblies shall be supplied by bidder

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3.4.5.3

Date : 12.08.08 Page 10 of 24 Revision No. : A

Probe Assembly • • • • •

The probe assembly shall contain the measuring cell, heater, thermocouple, ceramic filter and provisions for reference and calibration gas connections. The measuring cell shall be zirconia type specific for oxygen. The cell shall be calibrated over a range of 0.1 to 20.9% oxygen. A calibration curve shall be furnished with each cell. The probe assembly shall be flanged to the shield assembly. Probe assembly shall be suitable for operating over sample temperature upto 750ºC.

For higher temperature the probe may be located outside the furnace and eductor is to be provided for drawing sample out of furnace. 3.4.5.4

Control Unit • • •

3.4.5.5

The control unit shall contain all required controls, indications including temperature control for normal system operation and shall also provide output signal. A solid state temperature controller shall maintain cell temperature. Temperature sensor shall be ISA type K thermocouple. Temp controller shall shutoff heater power incase of thermocouple burn out.

Reference Gas Control • • •

Reference gas shall be flow and pressure controlled. Flow shall be controlled by rotameter with needle valve. Pressure shall be controlled by self-actuated pressure control valve provided with pressure gauge.

3.4.5.6

It shall be possible to change the range of measurement from the front panel of the control unit.

3.4.5.7

Following performance characteristics shall be met, as a minimum : Accuracy Repeatability Response time

± 2% of full scale ± 0.2% of full scale approx. 15 seconds for 63% response

3.4.6

FLUE GAS ANALYSERS

3.4.6.1

Flue gas monitoring system typically used for measuring emissions of heaters, stacks etc. Typical components measured shall be SOx, NOx, CO / CO2, O2 , suspended particulate matter and Opacity. type for SOx and NOx and extraction type for CO / CO2 with principle to meet the required specification and performance unless otherwise specified. Flue gas analysers for emission monitoring shall meet all EPA, OSHA requirements.

3.4.6.2

Probes shall be provided with necessary filter and material suitable for process and temperature condition. Dilution shall take place near the probe where dilution is specified. Sample tubes shall be SS for dilution systems and electrically traced and armoured Teflon tubes may be used for extraction systems. The sample conditioning system shall provide a fast loop condensate knock off system

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Date : 12.08.08 Page 11 of 24 Revision No. : A

3.4.6.3

In general, NDIR principle for CO / CO2, UV for SOx and Chemiluminescence for NOx detection shall be used . However, any proven superior detection system is also acceptable.

3.5

CALIBRATION

3.5.1

Analyser Vendor shall provide a two-year supply of certified calibration sample, and all equipment necessary for its field installation, including valves, pipe fittings, etc. Calibration sample injection shall be by manually operated valves at the analyser location.

3.5.2

Gas or liquid samples that deteriorate with time are not acceptable for field calibration. Examples of samples having a composition that deteriorates with time if stored in a cylinder include: - hydrogen or gas mixtures, - hydrogen sulphide in gas mixtures, - moisture in gas mixtures, and - samples with components present in amounts less than 20ppm.

3.5.3

If calibration samples cannot be provided due to restrictions on para.3.5.2, the Vendor shall propose an alternative field calibration procedure.

3.5.4

During calibration, the deviations of actual calibration from the calibration curve supplied by vendor shall be within + 10% of the specified value. If deviations within +/- 10% are not achieved at site, then necessary modification to the analyser system shall be done by vendor without any cost implication to Owner

3.5.5

For each gas Chromatograph, a dual cylinder carrier gas system shall be dedicated one to each chromatograph providing automatic switchover to standby cylinder when the first cylinder is exhausted. Number of cylinders supplied by vendor shall be adequate for 2 years continuous operation. In case of dual range of measurement, separate calibration standard for each range shall be provided. Calibration standard supplied by vendor shall be adequate to last six months. Also, Fuel gas cylinders for FID/FPD detector for three months continuous operation Each of the calibration gas and fuel gas cylinders shall be provided with two stage pressure regulator. For carrier gas manifolds, pressure regulator shall be provided on the manifold for each cylinder.

3.5.6

All analysers shall be calibrated using a test sample showing 50% of scale reading for the component of interest. Deviation of actual calibration from the calibration curve supplied by vendor shall be within + 1% of span.

3.5.7

Repeatability shall be demonstrated for a period of at least 8 hours continuously using a standard sample, unless otherwise specified. For infra-red/ultra-violet analysers, the preparation of components in the test sample shall be changed to confirm the absence of interference from components other than components of interest.

3.6

CHROMATOGRAPHS

3.6.1

Chromatograph shall be microprocessor based and constructed in accordance with basic principles of API-RP 550. The Gas Chromatograph system shall in general, consist of the following :- Sample conditioning system including sample probe - Chromatograph analyzer

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DOCUMENT NO : 44-LK-5100-00/J.02/0013-A4 STANDARD SPECIFICATION FOR PROCESS STREAM ANALYSERS AND CHROMATOGRAPHS

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Date : 12.08.08 Page 12 of 24 Revision No. : A

Programmer / Controller Gas Cylinders for calibration standards, carrier gas and fuel gas. Communication Interface

3.6.2

Process Stream sampling shall be continuous. Following performance characteristics shall be met as a minimum - Sensitivity shall be + 0.5% of span. - Reproducibility shall be + 1 % of span. - Accuracy shall be + 2 % of span. The analyser performance shall be within the specifications when the supply voltage changes by + 10 % of the specified value and supply frequency change by + 3 Hz of specified value. Battery back-up shall be provided for the volatile memory.

3.6.3

Components of any sub-assembly that requires removal maintenance shall be removable without having to disassemble any other components. Such components include items like stream selector valve, sample inject valves, filters, pressure regulators, plug-in circuit cards and detector cells.

3.6.4

Sampling valves shall be of special design to minimize peak tailing and baseline separation problems.

3.6.5

The chromatograph chamber shall be maintained at a constant temperature level. When the detector is of the thermal conductivity type, the temperature shall be maintained within + 10 C. Where multiple temperature controlled zones are involved in a single chromatograph, each zone shall be well insulated so that the temperature of one zone does not affect that of another. All the temperature controlled zones shall be operated at a temperature well above the maximum ambient temperature. Provision shall be made for manual temperature control.

3.6.6

The carrier gas system shall be complete with the supply of carrier gas bottles and instrumentation for flow control. The carrier gas system shall use minimum of threaded connections and fittings. These shall not be lubricated. Whenever hydrogen gas is used as carrier gas, the associated fittings and enclosures shall be made flameproof to IEC Zone 1 Group IIC requirements.

3.6.7

With each chromatograph, vendor shall provide a pressure switch to shut off power supply to the detector during loss of carrier gas flow, so as to prevent any damage to the detector.

3.6.8

All electrical components of the chromatograph shall be suitable for the electrical area classification specified and shall be certified by statutory body. Base line drift during one analysis cycle, without auto-zero, shall be less than 1% of autozero adjust span.

3.6.9

Column life shall be expected minimum of six months during normal operation. One spare set of columns shall be provided with each chromatograph. For calibration blends, stability will be 1 year from date of commissioning.

3.6.10

Vendor shall supply the following items with each chromatograph: - carrier gas specification, and - a device for measuring all flows during an analysis cycle. This may be a portable burette with soap solution, a calibrated draft gauge or permanently mounted rotameters.

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3.6.11

As a minimum, the following alarms shall be provided unless stated otherwise :Low Sample Flow Low Instrument air pressure alarm Low carrier gas pressure alarm Low detector Flame fuel pressure alarm Low detector flame air pressure alarm

3.6.12

The programmer shall be dedicated to each chromatograph and shall be an integral part of each chromatograph in this field. Programmer shall do the following as a minimum :properly control the analysis cycle, provide chromatogram outputs to strip chart recorder, provide hardwired analog outputs for each components to analysis, provide digital output to communication interface device, automatic zero adjustment and calibration of the chromatograph system. Maintenance diagnostics to be included in the software to allow rapid trouble-shooting in the event of system malfunction. Audio-visual alarms shall be provided for detector temperature deviation and zero off-set.

3.6.13

On power failure or on communication failure between chromatograph and programmer, the chromatograph shall revert to safe condition (back flush).

3.6.14

The communication interface is the device which serves as the final interface between the chromatograph and purchaser’s DCS or host computer. Unless otherwise specified, the communication interface shall have the following capabilities: -

Communicate the values for all measured process variables in the DCS in a form (scaled variable or engineering units) consistent with the DCS data highway. Each process variable will be designated by a unique point identification or address. For multistream analysers, the same component will have a unique point identification or address for each stream.

-

Individual component output of the chromotograph shall be transmitted to DCS in the form of 4-20mA signal

-

Communicate an “Analysis results ready” discrete signal to the DCS for each chromatograph. Each ready signal shall have a unique point identification or address and multistream analyser shall have one for each sample point.

-

Communicate the sample point being used currently to the DCS for multistream analysers.

-

Communicate individual chromatograph diagnostic alarm to the DCS for display and use in DCS control strategies. This alarm must include a maintenance diagnostic i.e. technician working on a chromatograph, if not provided separately.

-

Communicate selection of measurement range, stream and calibration sample selection from DCS to chromatograph for chromatographs with these features.

-

Communicate a system alarm for the common chromatograph communication.

-

Communicate a system alarm for the DCS interface hardware and software. The logic and control of multistream chromatograph is in the scope of the chromatograph vendor. The interface shall enable the console operator to select, which sample points are addressed by the chromatograph. The DCS operation

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Date : 12.08.08 Page 14 of 24 Revision No. : A

shall be able to select any combination such as remaining on one sample point or cycling through a selected subset of the possible points.

4.0

ANALYZER SHELTERS

4.1

SCOPE This specification define the minimum requirements of Analyzer shelters for housing industrial process analyzers and their associated piping, wiring and auxiliary instrumentation.

4.2

OBJECTIVES The objective in providing analyzer shelter are : -

To create a space within an otherwise Div. 1 area I in which under normal operating conditions a non hazardous atmosphere exists so that testing or calibration of analyzers and maintenance can be performed with opened casings and electrical circuits alive.

-

To create a good environment in which analyzers and their associated equipment are adequately protected against adverse weather conditions.

4.3

GENERAL

4.3.1

In general, all analysers shall be located in the shelter unless indicated otherwise. Where no shelter exists, analyser shall be installed in a free standing cabinet.The analyzer shelter shall be fully prefabricated, assembled, tested and shall be supplied as ready-to-install at project site with all items including analyzers and their accessories duly mounted, wired, tube and tested before shipment.

4.3.2

The arrangement of equipments shall be such that it provides enough access to front/back/sides of the equipments as necessary during normal operation as well as during startup and maintenance. Sufficient space shall be provided for work bench, signal and power cables entries and routing, power sockets utility, supplies, auxiliary and control equipments. Suitable arrangements shall also be made for locating devices like recorder, portable printers etc, near each equipment / Gas Chromatograph. All calibration cylinders and sample conditioning systems etc. shall be placed outside the shelter unless stated otherwise. The shelter shall be located as close as possible to the sample points as possible to reduce tubing lengths.

4.3.3

The housing shall be provided with fluorescent lamps to provide an illumination of 300 – 400 lux or more at the floor level, convenient for reading and carrying out maintenance and adjustments on the instruments / equipments. Fluorescent lamps shall also be provided outside of the analyzer shelter for carrying out the repair / adjustments on the equipments mounted on outside of the analyzer shelters e.g. sample conditioning systems etc.

4.3.4

Shelters shall be equipped with all safety measures like panic bar at the doors. Emergency alarm push buttons. LEL gas (hydrocarbon) detectors, Fire detection system, warning panels, Fire extinguishers, wash basin etc.

4.3.5

Shelter shall be provided with ventilation and air conditioning to maintain the temperature

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and humidity suitable for the analyzers stable performance and human comfort. 4.3.6

All electrical equipments, fittings, fixtures shall be Flame proof suitable for hazardous area classification.

4.3.7

Analyzer shelter / room shall be sized considering 25% additional spare space for future. Contractor to consider all other factors within the Analyzer / Room like A.C. System load, power load etc considering for analyzer to be installed within 25% additional space.

4.4

CONSTRUCTION

4.4.1

The shelter shall be constructed using materials capable of satisfying all the functional requirements and shall not be cause of any safety hazards at any point of time.

4.4.2

Design and construction of the shelter shall be self supporting type and shall be sized to house required analyzers sample conditioning system and other accessories. Shelters shall also be provided with suitable transportation arrangement.

4.4.3

The base structure of the shelter shall be constructed using suitable size 1” beams, channels, angles, welded properly and adequately. All structural members shall be sized to ensure structural rigidity and to prevent deformation during dragging, lifting, loading and unloading operation of the shelter.

4.4.4

The floor shall be fabricated from anti-slip and non-corresive SS plates as a minimum, strong enough to withstand load of all equipments and atleast 10 maintenance personnel also unaffected during transportation and various other obvious forces and shall be sealed to prevent any loss of ventilation pressure.

4.4.5

External side walls shall be stainless steel(SS 316) sheet of thickness 2 mm and internal walls shall be S 316 of thickness 2 mm. The walls of the shelter shall be strong enough to take load of the rack mounted analyzers, related sample conditioning system and associated accessories.

4.4.6

The shelter roof shall be capable of supporting the combined weight of atleast 4 men without permanent deformation and shall be sealed properly to prevent loss of ventilation pressure and entry of rain and jet water.

4.4.7

Lifting of the complete shelter alongwith all analyzers, sample conditioning systems and associated accessories mounted in it shall be assured by means of suitably designed lifting lugs.

4.4.8

The walls and roof shall be insulated by using glass wool of high density and low thermal coefficient, thickness approximately 100 mm commensurate with the HVAC design. Higher insulation thickness, if necessary shall be provided by contractor

4.4.9

The shelter shall be provided with a main door and an emergency door opposite to main door. Both the doors shall be opening outwards, provided with wire reinforced safety glass window, automatic spring door closer opening by simple push, fitted with panic hardware for use incase of emergency. The main door shall be provided with outside pad lock holes. Warning light shall be provided at both the Main door and the emergency door indicating the Hydro Carbon presence within the shelter.

4.4.10

Extension roof (overhead) made of stainless steel sheet shall be provided along all the wall

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of the shelter over the sampling system for protection of the sampling system and maintenance personal from the direct weather conditions. The extension roof shall be over hanged atleast 1000mm outside the analyzer shelter. 4.4.11

A name plate of SS with the analyzer shelter number shall be fixed near the main foor and emergency door. Tag numbers of the analyzers shall be fixed near the main door. Tag numbers of each analyzers and all sampling system shall be fixed near the respective items. All inlet and outlet tubes / pipes shall be provided with tag number & proper identification numbers engraved in the stainless steel plate and shall have a common entrance and exit to / from shelter through gland plates. There shall not be criss-crossing of any tubing / piping. All tubing / piping shall be such that they drop to connect to consumers. All electrical wires / leads shall be identified inside the junction box / equipment by proper plastic ferrules. All cables shall be identified with SS plate engraved tag nos / identification numbers.

4.4.12

Provision shall be made for keeping all fast loop devices, distribution devices outside the shelter. A suitable restriction orifice shall be provided in each sample line to limit the sample flow not exceeding thrice the normal flow in the event of tube rupture / opening of the tube down the line.

4.4.13

All safety valve outlets shall be terminated in a common header of 2” NB schedule 80S SS 304 pipe and single outlet shall be provided outside the shelter with one non-return valve and lock open type 2” ball valve, Similarly all vents to atmosphere shall be terminated in a similar 2” NB Sch 80S SS 304 pipe and single outlet shall be provided with non-return valve and Lock open type 2” ball valve.

4.4.14

All atmospheric gas outlet line shall be equipped with protection from climatic condition.

4.4.15

All tubing work shall be done by using ¼” OD or 1/8” OD SS tube and swage lock flareless, double compression type fittings.

4.4.16

All wiring / tubing and all other erection work shall be done in accordance to API RP 550

4.4.17

All cable entries / outlets in the junction boxes / distribution boxes etc and to the analyzer shall be provided with double compression type certified flame proof cables glands suitable for the indicated hazardous area. The material of the same shall be Nickel plated brass.

4.4.18

All cabling and wiring works inside the shelter shall be in accordance with the international standard / practice being practised in industry for similar application, however the cables shall be armoured as minimum. All instrument cabling shall be terminated in junction boxes located outside the shelter such that only multicore cables are taken to control system. All cables to / from the shelter shall be through Multicable Transit (MCT) blocks to ensure gas tightness of the shelter.

4.4.19

Adequate number of fire and gas detectors shall be provided in the shelter to provide an advance warning of sample leakage or fire.

4.4.20

Dimensions and layout of each shelter offered shall be provided by contractor for Owner / JH&G review.

4.5

PAINTING Analyzer shelter shall be treated and painted as follows :-

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4.5.1

All surfaces including structures shall be sand blasted and grinding done and they are smooth and free of scale, rust etc.

4.5.2

Chemical treatment shall be done to remove rust, oil, entrapped impurities and other foreign materials.

4.5.3

If necessary suitable filler shall be applied to all pits and blemishes on surfaces.

4.5.4

The surface of the shelter shall be painted with three coats of sealing primer and surfaces and two coats of epoxy paint finish.

4.5.5

The other surfaces including those accessories shall be painted with two coats of sealing primer and surface and two coats of epoxy paint finish.

4.5.6

A final coat of finish paint of high grade epoxy paint shall be given at site after assembly and erection is over.

4.5.7

The finish of the final coat shall be semi gloss fixture to minimise light reflection.

4.5.8

Contractor shall supply atleast one kilogram of paint per shelter for final touch up to purchaser.

4.5.9

Exterior and inside colour of shelter shall be finalised during detailed engineering.

4.6

POWER SUPPLY

4.6.1

Following power supplies shall be provided for each shelter by contractor; − − −

4.6.2

240 V 50 Hz for the Air Conditioning system 240 V 50 Hz Single Phase for lighting (internal and external) system of the shelter. 110 V 50 Hz single phase for analyzers, alarm system, horn and other related accessories.

Main switches for all three power supply shall be mounted outside the analyzer house which shall be weather proof to IP55 and explosion proof suitable to the hazardous area classification. The three power supply cables will be terminated after the main switches inside the shelter in different junction boxes with terminals and switch fuse units for power distribution to the relevant equipments / items. Individual switches shall be provided for each instruments for independent deengisation of the items. “Power supply on” indication shall be provided on the main power supply line to each analyzer on PDB.

4.6.3

Two power sockets of 110 V 50 Hz and 230V, 50Hz supply for electrical tools or test equipments shall be provided at two corners of each shelter. Tag plate indicating the Voltage level shall be mounted near the socket.

4.7

Lighting

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4.7.1

Power supply for lighting insider and outside the shelter shall be 240 V 50 Hz.

4.7.2

Internal lighting shall be provided by fluorescent tube lamps to provide in illumination of 300 to 400 lux minimum at all places on the floor.

4.7.3

External lighting shall be under overhands to provide illumination sufficient for maintenance / repair work.

4.7.4

Lighting fixtures inside and outside the shelter shall be suitable to the electrical area classification given above.

4.7.5

Lighting switch shall be provided outside the shelter near to the main door.

4.8

HVAC SYSTEM

4.8.1

Heating Ventilation & Air Conditioning system shall be designed sufficiently to create a safe area inside the analyzer shelter by supplying fresh air and a good environment by controlling the climatic condition through air conditioner or heater as required.

4.9

Pressurisation & Ventilation.

4.9.1

Analyzer shelter shall be designed as a pressurised and ventilated enclosure as per NFPA 496 standards. Pressurisation and Ventilation blowers / ducts shall be capable of maintaining a positive constant pressure of not less than 5 mm water column inspite a frequent door opening closing so that hazardous gas from outside entry is prevented. Provision shall be made for positive sealing of cable and sample entry points and maintaining air flow sufficiently large to carry away hazardous gases from leakages..

4.9.2

Contractor must furnish the pressurisation / purging details clearly indicating the following information and the standard to which the pressurisation of shelter is complied to ; − No of volumes of air changes for which shelter have been designed. −

4.9.3

Pressure maintanined within the Analyzer Shelter.

− Design code to which shelters pressurisation are being complied. Ventilation suction air shall be taken from a electrically classified safe area.through necessary filters, bug screens, damper, rain cap etc. The ducting shall be completely leak proof while passing through hazardous area. The suction duct shall be fabricated from sheet metal of SS and proper gaskets. Filters provided shall be cleanable type.

4.9.4

Two sets of blower each of 100% capacity shall be provided on each shelter. One shall be working all the time another shall run incase of failure of the master. The blower fans blade shall be made of no sparking material and motors used shall be certified from statutory body as suitable for the hazardous area classification. Blowers shall be interlocked to start automatically incase of failure of master. One number of blower shal be provided by contractor as spare and to be kept in the store.

4.9.5

Ventilation air shall escape via number of openings from the shelter. Blower duct opening location and air outlet opening shall be designed and located carefully to ensure sufficient turbulence and circulation to avoid accumulation of flammable gases in dead corners and to ensure required over pressure and to have enough volume of air changes.

4.10

Heating and Air Conditioning System

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4.10.1

Each Analyzer shelter shall be equipped with heating and air conditioning system to keep 0 0 the inside atmosphere of the shelter at a comparatively constant temperature of 26 +2 C with humidity less than 50% to obtain repeatability and reliability of the analyzers and also a comfortable working environment for workman.

4.10.2

Heating shall be done by properly designed steam coil heater placed in ventilation duct itself. Steam circuit shall be provided with thermal regulating valve for automatic control of steam flow with respect of temperature of analyzer shelter if available.

4.10.3

A split type air conditioner having an indoor and outdoor unit shall be provided for cooling inside the shelter for safe area, The air conditioner shall be direct expansion type. However for hazardous area (Zone 1/Zone 2) Ex-proof HVAC to be provided.

4.10.4

The analyzer shelter manufacturer shall submit a certificate from the statutory authority in the country of manufacture that the housing design and construction meet in general the requirement of NFPA 496.

4.10.5

The shelter manufacturer shall ensure that all electrical items used for each shelter are suitable for electrical area classification. Certificate from statutory authority shall be furnished showing the suitability of every electrical items used.

4.10.6

In case of analyzer rooms provided by the contractor, construction shall be as per the specifications for the control room buildings. However, all above specifications are also applicable. Chemical filters shall be provided in the fresh air intake to protect the electronic equipment installed inside the analyser shelter against the corrosive gases like H2S, SO2 , NOX etc

4.10.7

5.0

TESTING AND INSPECTION When the analyser and associated sample conditioning equipment are completely assembled, they shall be subject to inspection by the Purchaser's representative and a factory test as follows:

5.1

The test shall be an operating test, and it shall be the Vendor's responsibility to provide all facilities to demonstrate the analyser in accordance with the purchase specifications.

5.2

The Purchaser shall witness and approve all factory tests and reserves the right to approve the test procedure.

5.3

Repeatability shall be demonstrated continuously for a period of eight hours minimum using a standard sample. For samples, which deteriorate over an eight-hour period, repeatability may be demonstrated by calibrating the analyser before and after eight hours of operation and comparing results of calibration. Results should check within ±1%.

5.4

Calibration shall be demonstrated with a test sample, giving approximately one half scale reading for the component of interest. The concentration of the component of interest for this test shall be at least 25% of span difference from the concentration of the same component in the standard sample used for the repeatability test.

5.5

For chromatographs, a chromatograph of a standard calibration sample is required before auto-zero. This chromatogram shall show attenuator setting, chart speed, sample injection period, auto-zero period and switching points for all auxiliary valves such as 'back-flush'

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etc. Each peak on this chromatogram shall be labelled and attenuator setting noted. The composition of the standard sample shall appear on the chart with all elusion times of all components listed. 5.6

For infrared analysers, the proportion of the components in the best sample shall be varied to demonstrate freedom of interference from components other than those of interest.

5.7

A leakage test shall be conducted on the entire system. Maximum permissible leakage rates are as follows: - gas systems, 5% change per hour of the specified design pressure - liquid systems, no visible leakage.

6.0

DOCUMENTATION Copies of all instruction manuals and drawings shall be supplied as shown on the purchase order. These shall cover all components and shall include the following: -

7.0

internal wiring diagrams, interconnecting diagram showing all connections and shielding requirements. Markings for wire colour coding or numbering, and for terminal identification, shall be identical to those actually in the analyser, a drawing of pipe connections for the analyser and sample conditioning system, detailed installation instructions, calibration procedure, complete parts list, recommended spare parts for two years operation & commissioning troubleshooting procedure, a bill of materials for the sample conditioning system showing manufacturer's catalogue numbers for all major components, a copy of the factory inspection sheet, a copy of the testing organisations certificates showing the analyser's suitability for use in hazardous atmospheres. System wiring diagram including analyser / chromatograph, programme and communication interface etc. Cabling details including shielding / grounding requirements.

WARRANTY CONTRACT AND SERVICES

7.1

All components, parts and assemblies supplied and installed by the vendor shall be warranted against defects in design, material quality, workmanship and operation for a period of at least 24 months commencing from the date of handover to Owner upon successful completion of SAT or 36 months from the date of complete supply of materials whichever is earlier. Vendor shall be fully responsible for the manufacturer/sub-bidder/ sub-contractors/suppliers in this respect. Warranty services shall be provided by qualified & competent Engineer. During warranty period vendor shall carry out following activities/services/requirements without any cost implication. -

Periodical checking the proper functioning of Analyzer Hardware and Software. Attending and rectification of Hardware/Software failures/ problems immediately by repair or replacement of the failed components/faulty

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components/ faulty electronic cards. Providing all types of maintenance services for continuous operation of the systems/ sub-systems during the warranty period shall be totally vendor’s responsibility and shall be done without any cost implication. -

It shall be obligatory on the part of the vendor to carry out all types of modifications/ up-gradations of any hardware and software (both system software and application software) if the same are required for proper maintenance/running of the systems and the same is inevitable. In case any malfunction is revealed even during on-line operation after taking over of the systems by Owner the same shall be rectified by the vendor.These services shall be provided by the vendor during warranty period without any cost implication.

-

In the event of any malfunction of the analyzer system hardware/system software during warranty period, experienced service engineer shall be made available at site along with necessary spares within 48 hours of the recipt of such information from the owner.

-

In case of failure on part of vendor (i) to attend and rectify the problems logged/complained by Owner (ii) to replace any component/equipment for ensuring desired performance/ continues operation of the systems within the Warranty period.Owner reserves the right to invoke entire amount of performance bank guarantee that are valid at the time of invoking, irrespective of the value of the items which need to be replaced /rectified. -

Service or Maintenance personnel shall be able to receive 24-hour help-desk technical support to be provided by the system manufacturer.

-

Vendor shall supply maintenance spares, tools and tackles as required during the contract period.

-

During the warranty period, vendor shall visit the site once in a quarter and systematically carry out manufacturer’s recommended preventive maintenance. The Preventive Maintenance involves complete periodic overhaul of the system/sample handling system, inspection of the hardware and software, fault prediction, inspection of power supply quality, environmental operating condition checks, calibration checks, major repairs/replacements and detailed reporting. Vendor shall carry out routine condition monitoring and routine servicing of the Analysers and other associated equipment in the refinery installed by vendor.

-

The service contract shall be compulsory and the Owner shall have the right to accept or reject the bid based on the non compliance in meeting service contract.

-

Vendor should provide all updates, new releases of the software during the warranty period and shall be provided without cost implication.

-

Vendor shall submit Performance Bank Guarantee for 10% of the order value for warranty services.

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7.2

Date : 12.08.08 Page 22 of 24 Revision No. : A

POST WARRANTY COMPREHENSIVE ANNUAL MAINTENANCE CONTRACT (PWCAMC) FOR THE ANALYSERS AND THE ASSOCIATED AUXILIARIES -

Vendor shall quote for PWCAMC for the offered system for a period of 5 years from the date of completion of warranty period. There shall be 4 regular visits and 2 emergency visits every year. Vendor shall ensure proper functioning of the analysers with the associated systems including Sample Handling System.

-

Vendor shall submit proposal in the bid to provide extended service/maintenance agreements for up to 5 years after completion of warranty period. The agreement shall be renewable yearly.

-

Vendor to note that while carrying out the PWCAMC activities, Owner’s engineers shall oversee/associate with the vendor’s service engineer. Also onjob training to Owner’s engineers shall be imparted under this scope.

-

PWCAMC shall include all items being supplied by vendor, including any bought out items but not limited to the following: Labor and materials, at no additional cost to repair any analyzer. Labor and materials, at no additional cost to provide tests and adjustment to analyzer.

-

Payments for PWCAMC services shall be post services rendered i,e payments shall be made monthly on satisfactory rendering of service on production of certified service report and invoice. Vendor shall provide performance bank guarantee (PBG) equivalent to 10% of the amount for each year of 5 years of PWCAMC.Owner reserves the right to invoke part or full bank guarantee amount in case of poor performance of system or poor PWCAMC support provided by the vendor at any stage during PWCAMC period. Owner’s decision in this regard shall be final and shall be binding to the vendor.

-

Following are the requirements with respect to PWCAMC.

-

Periodical checking of the proper functioning of Analysers with the associated systems including Sample Handling System. Attending any failure immediately by repair or replacement of the failed component. Provide system maintenance and repair of system or workmanship defects during the year PWCAMC period free of charge (parts and labor).

-

It shall be obligatory on the part of vendor to modify and/or replace any Analyser hardware and modify/correct/upgrade the operating application and diagnostics software without any additional cost, in case any malfunction is revealed even during on-line operation after taking over by the Owner with in the PWCAMC period.

-

In case of failure on part of Vendor, to attend to the complaints that are raised by the Owner or to replace any component/equipment for ensuring desired performance from the DCS, within the PWCAMC period, Owner reserves the right to cancel the PWCAMC and withhold any payments payable to the party irrespective of the value of the items which need to be replaced /rectified.

-

Service or maintenance personnel shall be able to receive 24-hour help-desk technical support provided by the system manufacturer.

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-

The offer for PWCAMC shall be compulsory and the Owner shall have the right to accept or reject the bid based on the non compliance to meet Owner’s PWCAMC requirement.

-

The proposal shall include supply of maintenance spares, tools and tackle as required; travel, boarding & lodging of service engineer. The bid shall be made year wise up to 5 years and the price validity shall be available for the entire period of contract.

-

In the event of any malfunction of the Analysers and associated equipment, experienced service engineer shall be made available at site within 12 hours on the receipt of such information from Owner.

-

In case any hardware /software used from Owner’s stock, it shall be replaced by Bidder/Contractor with in 7 days with no cost to Owner. Vendor shall maintain a record of all faults during post warranty period.

The services under Post Warranty Maintenance Agreement, including supply of spare parts and services, shall broadly comprise of: - Preventive Maintenance. - Periodic Maintenance. - Emergency Service. Preventive Maintenance. This involves complete periodic overhaul of the analysers, inspection of the sample handling system and checking of diagnostic software, environmental operating condition checks, calibration checks and detailed reporting. This visit is in addition to visit required for periodic maintenance. -

Periodic Maintenance: This involves site visits, minimum six (6) times in a year (total days expected 24 days in a year), schedule of visits to be discussed and finalised jointly between Bidder/Contractor and HPCL after placement of order/delivery. It shall include inspection of general healthiness of the system, study and advice on daily maintenance, inspection of analyzers, if any problem is reported, and running of diagnostic software and test programs, on-line servicing and solving reported problems. Checks shall be conducted on-line Analyzers.

-

Emergency Service: In the event of any malfunction of analyser during this period, service Engineer must report at site within 12 hours of report of failure, with necessary spares. The system must be brought back within maximum 24 hours after reporting at site.

-

LOGISTIC SUPPORT: Bidder/vendor has to submit the duly signed logistic support agreement for the offered system for minimum 10 yrs support, while submitting the offer. Without the same, offer will be technically rejected.

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8.0

Date : 12.08.08 Page 24 of 24 Revision No. : A

REFERENCE STANDARDS. Following applicable codes and standards shall be referred for analyzer systems. BS EN-50054

Electrical Apparatus for the Detection and Measurement of Combustible Gases – General Requirements and Test Methods.

BS-EN-50057

Performance Requirements for Group II Apparatus Indicating upto 100% LEL

API RP-55

American Petroleum Institute Conducting Oil and Gas Producing & Gas Processing Plant Operations Involving Hydrogen sulphide.

API

American Petroleum Institute. Manual on Installation of Refinery Instruments and Control Systems (RP 550): Part II – Process Stream Analysers. Section 2 – Process Chromatographs