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Process Industry Practices Process Control

PIP PCEPA002 Process Analyzer Project Implementation Guidelines

PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES In an effort to minimize the cost of process industry facilities, this Practice has been prepared from the technical requirements in the existing standards of major industrial users, contractors, or standards organizations. By harmonizing these technical requirements into a single set of Practices, administrative, application, and engineering costs to both the purchaser and the manufacturer should be reduced. While this Practice is expected to incorporate the majority of requirements of most users, individual applications may involve requirements that will be appended to and take precedence over this Practice. Determinations concerning fitness for purpose and particular matters or application of the Practice to particular project or engineering situations should not be made solely on information contained in these materials. The use of trade names from time to time should not be viewed as an expression of preference but rather recognized as normal usage in the trade. Other brands having the same specifications are equally correct and may be substituted for those named. All Practices or guidelines are intended to be consistent with applicable laws and regulations including OSHA requirements. To the extent these Practices or guidelines should conflict with OSHA or other applicable laws or regulations, such laws or regulations must be followed. Consult an appropriate professional before applying or acting on any material contained in or suggested by the Practice.

This Practice is subject to revision at any time.

Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at Austin, 3925 West Braker Lane (R4500), Austin, Texas 78759. PIP member companies and subscribers may copy this Practice for their internal use. Changes, overlays, addenda, or modifications of any kind are not permitted within any PIP Practice without the express written authorization of PIP.

PRINTING HISTORY August 2000 August 2006 Issued Complete Revision

Not printed with State funds

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Process Industry Practices Process Control

PIP PCEPA002 Process Analyzer Project Implementation Guidelines

Table of Contents 1. Introduction................................. 2
1.1 Purpose ............................................ 2 1.2 Scope ............................................... 2

2. General References .................... 2

2.1 Process Industry Practices .............. 2 2.2 Industry Codes and Standards ........ 2 2.3 Information Resources ..................... 3

3. General ........................................ 3 4. Tasks and Deliverables .............. 4

4.1 4.2 4.3 4.4 4.5 4.6 4.7 Conceptual Design........................... 4 Production Design............................ 5 Implementation ................................ 6 Detailed Design................................ 8 Installation ...................................... 11 Commissioning/Start-up/Turnover . 11 Project Completion......................... 12

5. Project Scheduling ................... 12

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1.

Introduction
1.1 Purpose This Practice provides guidelines for the design, specification, purchasing, and installation of process analyzer systems for major capital projects. 1.2 Scope This Practice describes the guidelines for implementation of process analyzer systems. The successful implementation of a process analyzer project requires the knowledge, integration, and management of multi-disciplinary engineering skills and resources that may bridge several different organizations. The detailed information on Tasks and Deliverables provided in this Practice assumes a typical project. However, depending upon the scope of a given project and the organizational structure defined for that project, the tasks defined under the Task s and Deliverables for participating organizations may change. This Practice should be used to assist in assessment and definition of roles and responsibilities for those tasks required for a given project.

2.

General References
Applicable parts of the following Practices, industry codes and standards, and references shall be considered an integral part of this Practice. The edition in effect on the date of contract award shall be used, except as otherwise noted. Short titles will be used herein where appropriate. 2.1 Process Industry Practices (PIP) PIP PCCPA001 - Process Analyzer System Design Criteria PIP PCEPA001 - Process Analyzer System Engineering Guidelines PIP PCSPA001 - Process Analyzer Project Documentation Data Sheet Instructions PIP PCSPA01D - Process Analyzer Project Documentation Data Sheet PIP PCSPA002 - Process Analyzer System Data Sheet Instructions PIP PCSPA02D - Process Analyzer System Data Sheet PIP PCSPA003 - Process Analyzer Shelter Data Sheet Instructions PIP PCSPA03D - Process Analyzer Shelter Data Sheet PIP PCSPA004 - Process Analyzer Bid Proposal Data Sheet Instructions PIP PCSPA04D - Process Analyzer Bid Proposal Data Sheet PIP PCIPA001 - Process Analyzer System Field Installation PIP PCTPA001 - Process Analyzer System Acceptance Testing 2.2 Industry Codes and Standards National Fire Protection Association (NFPA) NFPA 30 - Flammable and Combustibles Liquids Code

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NFPA 70 - National Electrical Code - Latest Edition NFPA 496 - Standards for Purged and Pressurized Enclosures for Electrical Equipment NFPA 497 - Recommended Practice for the Flammable Liquids, Gases, or Vapors and of Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas 2.3 Information Resources Clevett, K.J., Process Analyzer Technology, John Wiley & Sons, NY, NY. Cornish, D. C., Jepson, G., Smurthwaite, M.J., Sampling Systems for Process Analyzers, Buttersworth, London, England. Houser, E.A., Principles of Sample Handling and Sample System Design for Process Analysis, Instrument Society of America, Research Triangle Park, NC. Liptk, B.G., Instrumentation in the Processing Industries, Chilton Book Co., Radnor, PA. Sherman, R. E., Analytical Instrumentation Practices Guide for Measurement and Control, Instrument Society of America, Research Triangle Park, NC. Sherman, R.E., Process Analyzer Sample-Conditioning System Technology, Wiley Interscience, 2002, New York.

3.

General
3.1 The implementation of process analyzers on a major capital project can require the participation of only one or several of the following resource groups: a. Owner Company personnel. b. Engineering and Construction Electrical and Instruments (E&I) engineering section (E&C) contractor c. Analyzer Systems Vendor (ASV) d. Analyzer Original Equipment Manufacturer (OEM) 3.2 How these different organizations interact to produce a successful analyzer project can vary depending upon the expertise of each group and the stage of the project. A typical capital project includes, but may not be limited to, the following stages: a. Conceptual design b. Production design c. Implementation d. Detail design e. Installation f. Commissioning/startup/turnover

g. Project completion 3.3 Successful implementation of a project requires continuity of personnel throughout the execution period of a project. In addition to minimizing the overall cost of the

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project, all efforts should be taken to align resources and minimize duplication of effort. A matrix can be prepared in a spreadsheet or word-processing format to show the tasks required at each stage in the project, along with each partys agreed role (i.e., lead, approval, review, and information only).

4.

Tasks and Deliverables

A brief explanation of the analyzer project activity associated with each of the project stages is defined in this section. Specific analyzer-related tasks and deliverables for each design stage are further detailed for each of the participating organizations. 4.1 Conceptual Design 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 The conceptual design phase, which may follow piloting activity, is used to generate process flow diagrams (PFDs). Piping and instrument drawings (P&IDs) may be started during this stage of a project. This activity normally includes the participation of the Owner Company R&D and Engineering organizations. If a production-scale pilot plant facility is included in this stage, the services of an E&C contractor may also be required. At this stage of a project, the definition of process analyzer needs is often limited to a conceptual like to have or must have. However, including process analyzer resources at this stage of process development and design is critical. This may be the only opportunity to develop, test, and evaluate process specific on-line analysis techniques for perceived analysis needs before implementation. Owner Company 4.1.6.1 Develop PFDs. 4.1.6.2 Define preliminary analysis requirements. 4.1.6.3 Develop methods for Owner Company proprietary analytical technology. 4.1.6.4 Develop analysis systems design concepts. 4.1.6.5 Initiate preparation of PIP PCSPA02D utilizing PIP PCSPA002. 4.1.6.6 Specify acceptable analytical technologies and vendors. 4.1.6.7 Develop acceptable vendor lists for ASV, analyzer OEM, and system components. 4.1.6.8 Develop preliminary of P&IDs (study drawings). 4.1.6.9 Define project Tasks and Deliverables.

4.1.6

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4.2

Production Design 4.2.1 During the production phase of a project, PFDs are further refined, the plant layout or general arrangement is defined, and P&IDs are developed and completed. On-line process analyzer requirements, including sample tap locations, process operating conditions, and specific analysis requirements, are defined during this stage. An E&C contractor typically completes the detailed design of a production facility, in conjunction with designated representatives of Owner Company. The tasks outlined in the following sections are completed during this stage of the project. These tasks may not be presented in a timeline sequence because the project participants often complete them in parallel. Owner Company Tasks and Deliverables 4.2.5.1 4.2.5.2 4.2.5.3 4.2.5.4 4.2.5.5 4.2.5.6 4.2.5.7 4.2.5.8 4.2.5.9 Recommend sample point and sample return requirements. Recommend sample line materials of construction, insulation, and heating requirements. Recommend acceptable materials of construction for processwetted sample-handling components. Recommend analyzer calibration/validation method. List available support utilities. Recommend alarm and signal requirements. Recommend analyzer system host computer interface. Provide typical flow diagrams for sample system. Provide laboratory sample station requirements.

4.2.2

4.2.3 4.2.4

4.2.5

4.2.5.10 Recommend shelter type: a. Type I - field mounted. b. Type II - freely ventilated. c. Type III - climate controlled. d. Type IV - controlled for area classification reduction. 4.2.5.11 Update PIP PCSPA02D utilizing PIP PCSPA002. 4.2.5.12 Produce PIP PCSPA03D utilizing PIP PCSPA003. 4.2.5.13 Recommend maintenance support peripherals (e.g., cylinder racks, apron around shelter, walkways, maintenance data highways, etc.). 4.2.5.14 Prepare preliminary process analyzer budgetary cost estimate based on data available and defined design requirements. 4.2.6 E&C Contractor Tasks and Deliverables 4.2.6.1 Define electrical area classification for each analyzer location.

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4.2.6.2 Incorporate maintenance support peripherals. 4.2.6.3 Locate sample point and sample return points on P&IDs. 4.2.6.4 Complete P&ID representation of alarm and signal requirements between analyzers, sample systems, and host computer. 4.2.6.5 Complete drawing representation or written functional description of host computer interface and control functions for any automated sampling, calibration, flushing, inerting operations, and valve sequencing. 4.2.6.6 Prepare flow diagrams for sample systems. 4.2.6.7 Locate and identify laboratory sample stations on P&IDs. 4.2.6.8 Update PIP PCSPA02D utilizing PIP PCSPA002. 4.2.6.9 Update PIP PCSPA03D utilizing PIP PCSPA003. 4.2.6.10Locate process analyzer shelter(s) on plot plan or model. 4.2.6.11Identify all relevant local and industry standards and certification requirements. 4.2.7 ASV Tasks and Deliverables Provide budgetary quotations. 4.2.8 Analyzer OEM Tasks and Deliverables Provide budgetary quotations. 4.3 Implementation 4.3.1 The basic data for the process analysis requirements that are developed during the conceptual and production design stages are used during implementation to define sample transport, sample conditioning, and utility support requirements for each analyzer system installation. Depending upon the roles and responsibilities that have been defined for a given project, the Owner Company and/or the E&C contractor typically assumes the responsibility for developing the analyzer system installation information. The tasks outlined in the following sections are completed during this stage of the project. These tasks may not be presented in a timeline sequence because the project participants often complete them in parallel. Owner CompanyTasks and Deliverables 4.3.4.1 Review ASV bid package, drawings, and specifications prepared by E&C contractor. 4.3.4.2 Review and approve ASV bid package. 4.3.5 Owner and/or E&C Contractor Tasks and Deliverables 4.3.5.1 Provide physical location information for all analyzer sample taps and sample return points. Include physical orientation (vertical vs.

4.3.2

4.3.3

4.3.4

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horizontal pipe run, nozzle orientation: top vs. side of pipe, etc.) and accommodate maintenance accessibility. 4.3.5.2 Locate and orient all field-mounted analyzers, pre-conditioning assemblies, analyzer enclosures, analyzer shelter, and cylinder racks to assure maintenance accessibility and tie-in to field piping and utility support. 4.3.5.3 Define interconnection requirements for power, analog/digital, and fiber optic signals for host computer and process field wiring. 4.3.5.4 Complete PIP PCSPA02D. 4.3.5.5 Complete PIP PCSPA03D utilizing PIP PCSPA003. 4.3.5.6 Compile all applicable standards, codes, or approved supplier lists that will impact the design, fabrication, and installation of the analyzer systems, including those listed in the References. 4.3.5.7 Prepare Overview Document to describe the project scope. 4.3.5.8 Prepare and complete PIP PCSPA01D. 4.3.5.9 Define ASV and analyzer OEM installation, start-up, and commissioning requirements. 4.3.5.10 Prepare bid specification for analyzer system project. 4.3.5.11 Prepare lower sections of PIP PCSPA04D utilizing PIP PCSPA004. 4.3.5.12 Participate together in ASV bid evaluation. 4.3.5.13 Place order to ASV for process analyzer project. 4.3.6 E&C Contractor and/or ASV Tasks and Deliverables 4.3.6.1 Design functional details for sample-handling system: a. Single vs. multi-point b. Differential pressure vs. pumped vs. aspirated sample transport c. Fast loop and analyzer flow requirements. d. Auto vs. manual stream switching e. Auto vs. manual calibration and validation 4.3.6.2 Design fabrication details for sample-handling system: a. Layout b. Mounting and installation considerations 4.3.6.3 Complete and submit bid proposal for process analyzer package in accordance with PIP PCSPA04D. 4.3.7 Analyzer OEM(s) Tasks and Deliverables Complete applications assessment or development for unique analysis requirements.

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4.4

Detailed Design 4.4.1 The data developed during conceptual design, production design, and implementation stages of the project are transmitted to an ASV and/or an analyzer OEM for development and production of design documentation for each analyzer system and installation design details. Following approvals by both the owner and E&C contractor, the systems are released for fabrication. Upon completion of fabrication, the systems are inspected and subjected to acceptance tests by owner and E&C contractor. The tasks outlined in the following sections are completed during this stage of the project. These tasks may not be presented in a timeline sequence because the project participants often complete them in parallel. Owner and/or E&C Contractor Tasks and Deliverables 4.4.5.1 Purchase analytical instruments and/or obtain proprietary in-house instruments. Instruments may be drop-shipped to ASV or others for modifications as required to meet installation electrical area classification, all local electrical codes, and sample system integration. 4.4.5.2 Conduct analyzer systems safety review before final approval for fabrication. 4.4.5.3 In conjunction with ASV, design and provide foundation and structural supports required for analyzer shelters, HVAC cylinder racks, utilities support, etc. 4.4.5.4 Participate in Analyzer OEM acceptance tests of process analyzers. 4.4.5.5 Approve all documentation including: a. Specifications b. Drawings c. Acceptance test procedures d. Inspections 4.4.5.6 Participate in Factory Acceptance Tests (FAT) of fabricated analyzer systems. 4.4.5.7 Define maintenance and support training requirements. 4.4.5.8 Use Document Control for tracking all manuals, drawings, etc., for the analyzer project. 4.4.5.9 Supply ASV with a block of instrument loop numbers for identifying instruments on analyzer system P&IDs and other drawings as required. 4.4.5.10 Review and approve all specifications, drawings, and documents that require interfaces/interconnections to process equipment or services as required to ensure that systems supplied by Owner Company or ASV will meet all site design and installation criteria.

4.4.2 4.4.3 4.4.4

4.4.5

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4.4.5.11 Design and provide to the ASV all sample and sample return line routings and lengths. 4.4.5.12 For Type III and Type IV shelters, design and provide to the ASV the routing, distance, and support needs for the fresh air intake stack. 4.4.5.13 Design signal and alarm cabling and routings. 4.4.5.14 Design and provide utility support requirements as defined by Owner Company and/or the ASV. 4.4.5.15 Complete PIP PCSPA01D utilizing PIP PCSPA001. 4.4.5.16 Owner shall supply certificates of manufacture written in the destination language and authenticated by the local embassy, consulate, or commercial attachs for countries outside the European Community. The owner should be responsible for U.S.-purchased equipment. 4.4.6 ASV Tasks and Deliverables
4.4.6.1 Analyzer Shelter

1. Design, purchase, and fabricate analyzer shelter(s) including a. HVAC b. Orientation c. Utility connections d. Location e. Layout f. Sizing g. Mounting and orientation of analyzers h. Sample probes i. Sample systems j. Pre-conditioning assemblies k. Other supplied accessories in accordance with bid specification, installation criteria, electrical area classification, and any other related project requirements. 2. Prepare written specifications for all major equipment and system components that are not being purchased by owner and/or E&C contractor (e.g., HVAC system). 3. Provide shelter pressurization and airflow calculations required to purge for toxic gas, combustible gas, or asphyxiant gas leaks into the interior of the shelter. 4. Design sample return interface including sample recovery systems, vents, drains, process headers, etc. 5. Design for all utility requirements including load and consumption calculations.
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6. Design for all cabling requirements. 7. Provide required certifications. 8. Prepare and provide detailed documentation for the installation by the E&C contractor for all analyzer systems shelters and ancillary equipment. 9. If required, provide preliminary drawings for outline and mounting dimensions and interconnections.
4.4.6.2 Analyzer Systems

1. Design and provide calculations for sample line size in accordance with sample loop residence and analyzer response time requirements. 2. Ensure that sample system design includes the following: a. Calibration and validation systems with standards as defined on the data sheets. b. Temperature, pressure, flow indication, and control. c. Suitable materials of construction to meet process tap and return conditions. 3. Prepare and issue all drawings in accordance with PIP PCSPA01D utilizing PIP PCSPA001. 4. Purchase all analyzers not included in owner alliance agreements and associated hardware required to fabricate and mount all analyzer sample system enclosures, shelters, and racks. 5. Fabricate all process analyzers systems, shelters, and racks. 6. Provide all material, test equipment, and personnel to conduct the Factory Acceptance Tests, including calibration gases and standard generators. 7. Host and conduct Factory Acceptance Tests for all process analyzers and associated hardware purchased by the ASV. Provide preliminary system test results to owner and E&C contractor. 8. Provide a list of start-up and commissioning spares and a list of spare parts for 2-year operation. 9. Identify any consumable or limited shelf-life items that may require special shipping requirements (e.g., pH electrodes). 4.4.7 Analyzer OEM Tasks and Deliverables 4.4.7.1 Provide the process analyzers as defined by the owner and E&C contractor or the ASV in accordance with PIP PCSPA02D. 4.4.7.2 Provide all information, documentation, software, and ancillary equipment as required for a fully operational and functional analyzer.

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4.4.7.3 Provide dimensional outline, electrical, and utility interconnection diagrams. 4.4.7.4 Provide all material and personnel to conduct the Analyzer OEM acceptance test. 4.5 Installation 4.5.1 4.5.2 The E&C contractor or a contractor designated by the owner normally handles the field installation of the analyzer systems. The tasks outlined in the following sections are to be completed during this stage of the project. These tasks may not be presented in a timeline sequence because the project participants often complete them in parallel. Owner and/or E&C Contractor Tasks and Deliverables 4.5.3.1 Complete site preparation 4.5.3.2 Install concrete foundations 4.5.3.3 Set major equipment 4.5.3.4 Install analyzer systems, including sample lines 4.5.3.5 In accordance with ASV installation detail drawings, purchase required materials for mounting and installing analyzer shelters and all field-mounted hardware, including sample lines and sample line heat trace termination kits. 4.5.3.6 Connect all interface points (e.g., piping, utilities, electrical, and instrumentation). 4.5.4 ASV Tasks and Deliverables 4.5.4.1 May provide on-site supervision for off-loading and site installation of all analyzers, shelters, or systems, including HVAC ductwork, sample probes, sample lines, and calibration systems in their supply. This may also include providing supervision for termination of field power, signal cabling, connection of all utilities, and mounting of all systems and ancillary equipment. 4.5.4.2 Prepare data books and training program for the operation, calibration, start-up, shutdown, maintenance, troubleshooting, and analyzer system diagnostics of the process analyzer systems, shelters, alarms, and safety systems. Provide copies of the data books as specified. 4.6 Commissioning/Start-up/Turnover 4.6.1 4.6.2 Commissioning is the demonstrated operation of the analyzer systems and all associated hardware and software. Start-up is the demonstrated operation of the analyzer systems with actual process samples.

4.5.3

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4.6.3

After successful commissioning, start-up, and a defined period of uninterrupted on-line operation, turnover (or transfer of ownership) of the systems to the owner is completed. Commissioning, start-up, and turnover typically involves resources from the owner, the E&C contractor, the ASV, and/or the Analyzer OEM. The tasks outlined in the following sections are completed during this stage of the project. These tasks may not be presented in a timeline sequence because the project participants often complete them in parallel. Owner and/or E&C Contractor Tasks and Deliverables 4.6.6.1 Participate in site start-up and commissioning of all analyzers and ancillary equipment. 4.6.6.2 If specified, issue requisition to ASV and Analyzer OEM to perform on-site start-up, commissioning, and training.

4.6.4 4.6.5

4.6.6

4.6.7

ASV Tasks and Deliverables 4.6.7.1 Provide on-site test procedures and test documentation requirements. 4.6.7.2 Provide start-up and commissioning requirements that refer to all ASV provided equipment analyzers, analyzer shelter, ancillary equipment, etc. 4.6.7.3 Provide start-up system with process samples. 4.6.7.4 Provide on-site training program for owner personnel on operation and maintenance of the equipment. ASV should complete training program documentation before site installation and complete training classes on site before commissioning. Proposal should include per diem rate (time, travel, and expenses) and numbers of days required for training.

4.6.8

Analyzer OEM Tasks and Deliverables Provide on-site start-up assistance and training as required.

4.7

Project Completion 4.7.1 The installation, commissioning, and start-up of an analyzer system may require field modifications or changes that can require updates to the project design drawings and documentation. Updating these documents to reflect the as-built condition of the installed systems is essential for maintenance and support of these systems. The E&C contractor, ASV, and/or the Analyzer OEM are typically involved in ensuring the accuracy of the as-builts.

4.7.2

5.

Project Scheduling
Table 1 provides notional parameters for consideration in establishing a schedule for an analyzer systems project.

Table 1 Analyzer Project Scheduling Elements

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Notional Time to Completion: Conceptual Design Production Design Implementation Analyzer pre-bid meeting(s) Issue request for bid Purchase order (PO) placement Owner, E&C contractor, and ASV kickoff meeting Detail Design Preliminary drawing submittals First pass approval drawings Process analyzer system safety review Final approval drawing submittal Release for fabrication Analyzer OEM inspections ASV Factory Acceptance Tests Release for shipment Spare parts list Final data books Installation Field installation completion date Commissioning/Start-up/Turnover On-site commissioning and training Plant start-up Turnover Upon installation completion 3-6 months after receipt on-site After plant start-up or 36 months after receipt on-site 13 months after receipt on site Maximum 30 working days after order placement Maximum 60 days after order placement Minimum 10 working days after receipt of approval drawings Minimum 10 working days after completion of safety review Upon final approval drawing sign-off As bid As bid After completion of Factory Acceptance Tests and punch list corrections 6 weeks before receipt of systems Maximum 10 workings days after receipt of systems 15 years. 12 years. 36 months. Maximum 30 days before bid due date Minimum 10 working days before bid due date Minimum 10 working days after receipt of bids Maximum 10 working days after order placement

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