Gas Chromatographs.pdf

8/19/2019 Gas Chromatographs.pdf

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TECHNICAL SPECIFICATION

GAS CHROMATOGRAPHSI4431E

DATE: 03 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 1 OF 10

TABLE OF CONTENTS

Section Title Page No.

1. GENERAL ......................................................................................................................................11.1 Scope..............................................................................................................................................1

1.2 KBR Documents, Codes, and Industry Standards .........................................................................1

2. DESIGN AND MATERIALS ...........................................................................................................2

2.1 General ...........................................................................................................................................2

2.2 Sample Probe .................................................................................................................................3

2.3 Sample Conditioning System..........................................................................................................3

2.4 Analyzer ..........................................................................................................................................6

2.5 Controller ........................................................................................................................................7

3. INSPECTION AND TESTING ........................................................................................................8

3.1 General ...........................................................................................................................................8

3.2 Nameplate Identification.................................................................................................................9

4. DOCUMENTATION ......................................................................................................................10

4.1 Manuals ........................................................................................................................................10

4.2 Radioactive Sources .....................................................................................................................10

4.3 Shipping Documentation...............................................................................................................10

4.4 Supplier Data Requirements.........................................................................................................10

4.5 Spare Parts ...................................................................................................................................10

5. SUPPLIER SUPPORT .................................................................................................................10

5.1 Training .........................................................................................................................................10

5.2 Field Support.................................................................................................................................10

1. GENERAL

1.1 Scope

1.1.1 Chromatographs shall be supplied in strict accordance with:

Attached Data Sheets

This Specification

KBR Purchasing Standard I2-1PS

1.1.2 Where special features or improvements over the standard specification are required, these will be

specified on the Instrument Data Sheets and shall be adhered to by the Supplier. The Supplier shall comply

with any local rules or regulations specified by the Purchaser.

1.2 KBR Documents, Codes, and Industry Standards

The following documents are referenced herein and form part of the Order. Additional KBR documents, whenapplicable, will be listed on the Requisition. The issue of KBR documents shall be as specified in the

Requisition. Current editions of the industry standards including all mandatory addenda in effect at the time of

the order shall apply unless otherwise indicated.

KBR DOCUMENTS

I2-1PS, "Purchasing Requirements for Instruments and Components"

AMERICAN PETROLEUM INSTITUTE (API)

API RP 550, "Installation of Refinery Instruments and Control Systems"

Part II - "Process Stream Analyzers" (WITHDRAWN)


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AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B1.20.1, "Pipe Threads, General Purpose (Inch)"

ASME B31.3, "Process Piping"

INSTRUMENT SOCIETY OF AMERICA (ISA)

ISA S50.1, "Compatibility of Analog Signals for Electronic Industrial Process Instruments"

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 6, "Industrial Control and Systems Enclosures"

NEMA 250, "Enclosures for Electrical Equipment (1000 Volts Maximum)"

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70, "National Electrical Code"

NFPA 496, "Purged and Pressurized Enclosures for Electrical Equipment"

2. DESIGN AND MATERIALS

2.1 General

2.1.1 The gas chromatograph Supplier shall quote the necessary hardware and services to provide a

completely assembled analyzer package suitable for installation inside of an analyzer shelter. The

chromatograph system shall in general consist of the following:

a. Sample Probes

b. Sample Transport and Conditioning Systems

c. Automated Stream Selection Manifold

d. Chromatograph Analyzer/Programmer

e. Maintenance Workstations and Printers (located in the control room)f. Recording Unit (located in the control room for generating chromatograms)

g. All equipment required for digital link communication with the plant DCS through a Honeywell CLM.

The Supplier shall identify and quote any other equipment and services necessary to satisfy the gas

chromatograph requirements for this project.

2.1.2 The transmitted signal shall be as shown on the Instrument Data Sheets. Terminology used in this

specification is defined in ISA S50.1.

2.1.3 In the event of a power source low voltage condition, below the minimum required for operation of any

part of the gas chromatograph, the equipment shall perform an orderly shutdown without creating any random

output or voltage ramps. Sample injection shall be inhibited until after the chromatograph oven reaches

operating temperature.

2.1.4 All process gas chromatographs shall be able to operate within conditions stated on the data sheet.

2.1.5 The attached Instrument Data Sheets specify the anticipated stream composition and process conditions

for each sample line to be analyzed. The Supplier shall be responsible that the entire sample

handling/conditioning system (probe, transport tubing, and sample system) will properly condition the process

sample. This responsibility is to ensure the analyzer receives a sample that can be properly and consistently

analyzed. The Supplier shall identify and quote all components required for the sampling systems, including the

sample probes, and sample system, but excluding the transport tubing. The sample system(s) shall be

completely assembled and tested. Any loose components shall be identified and kept to a minimum. All sample

system components shall be provided with a label stating function, range, and set point.


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2.1.6 Supplier shall furnish a comprehensive description of the equipment being quoted, including descriptive

bulletins that pertain to the subject proposal equipment. Information considered essential is a descriptive

drawing of the sample system proposed, having components identified with model numbers and material of

construction, brochure of all major components being offered, time of analysis, description of any other specialfeatures being furnished, accuracy, reproducibility of analysis and any exceptions to this specification.

2.1.7 Accuracy of analysis and percent drift over 24 hours shall be provided. The accuracy of the analyzer shall

be in accordance with Subparagraphs 2.4.10 a and b and the analyzer data sheets.

2.1.8 The Supplier shall provide dimensional drawings showing internal layout of the gas chromatograph

(including columns and detectors). Drawings shall also be provided for the sample valves detailing their

principle of operation and construction.

2.1.9 The Supplier shall provide in his quotation a complete list of utilities required (for each analyzer), such as

cooling water, instrument air, steam and electrical power. The list shall include quantities, flow rates, pressures,

voltage and other defining parameters for the utilities to be supplied by the owner, including minimum quality

and maximum pressure rating for all required utilities. All utilities shall be defined individually by the user (probe,

transport tubing, sample system, analyzer, etc.). In addition, the Supplier shall identify all consumables, such as

calibration and carrier gases, and provide anticipated rates of consumption for the analyzer systems proposed.

2.1.10 All electrical components, provided by the Supplier, shall be suitable for installation and operation in the

electrical area classification specified on the Instrument Data Sheets. Analyzers shall be approved for use in

the specified area classification to a standard that is recognized by the appropriate local authority. A label

providing information on the approval shall be permanently fastened to the analyzer.

2.1.11 The Supplier shall quote all necessary interconnecting cables (installed) between analyzer components

and related systems within the analyzer structure.

2.1.12 The Supplier shall recommend and quote any additional equipment required for the calibration,programming, and operation of the analyzer systems.

2.1.13 The Supplier shall respond in his proposal to each paragraph of this specification. Any exceptions taken

shall be noted on a paragraph by paragraph basis.

2.2 Sample Probe

2.2.1 The Supplier shall provide a probe design suitable for the functional and metallurgical requirements of

each application's specification. Flanged thermowell type probes are preferred.

2.2.2 The Supplier shall recommend any insulation and specify any utilities required at the probe location.

2.2.3 Requirements for winterization and protection against cooling due to ambient temperatures will bespecified.

2.3 Sample Conditioning System

2.3.1 The Supplier shall furnish all of the necessary equipment to condition and regulate the sample based on

inlet and outlet conditions specified on the instrument data sheets. The sample system shall consist of, but not

be limited to the following; filter, strainers, flow indicators, controllers, solenoid valves, pressure regulators,

vaporizers, pumps, aspirators, relief valves, special sample conditioners, and all other devices required to

prepare and condition the sample. Model numbers for each component shall be provided. The sample system

shall be designed and constructed with ease of maintenance as a prime consideration along with reliability and

simplicity. The guaranteed sampling system shall be assembled so as to minimize dead volume and transport

lag time. Pressures shall be reduced to safe operating levels at the sample system inlet.


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2.3.2 The sample system shall be completely assembled by the Supplier, unless noted.

2.3.3 The Supplier shall submit detailed drawing, including all specifications, of the complete sampling systemand analyzer showing all equipment connection sizes and connection description for approval. The

P&I Drawing shall also detail the sample system stream select manifold system. All component model numbers

and materials of construction shall be provided. The Supplier shall quote the sample system as an assembled

and pressure tested system, to be installed on the outside of the analyzer shelter. The Supplier shall provide

details for the sample return line and analyzer vent. Return pressures of all sample streams shall be provided.

2.3.4 Sample transport shall be as short as possible and preferably shall not exceed 90 seconds. This

maximum time is from the sample take-off point, located on the process piping, throughout the sample

conditioning system and to the analyzer. The system Supplier shall state, in his proposal, the maximum

transport time in his supplied sample system. Calculations for sample line sizing and sample transit times must

be submitted to the Purchaser for approval.

2.3.5 Sample lines (speed loop) for transporting the sample from the sample point to the analyzer shelter shall

be provided by others. The Supplier shall recommend heat tracing and insulation requirements for each sample

line. The Supplier shall quote vaporizing regulators for liquid service where required, to be located at the

sample point.

2.3.6 All wetted sampling system parts shall be a minimum 316 stainless steel, Viton A, Virgin TFE Kalrez, or

EPR gaskets and seals., unless otherwise specified on the Instrument Data Sheets. All fittings shall be 316 SS

Swagelok or Parker CPI unless greater corrosion resistance is required. All tubing shall be 316 SS (seamless,

bright annealed) unless greater corrosion resistance is required.

2.3.7 Sample systems with filter less than 10 microns shall include parallel filters and individual block valves.

Filter elements shall be removable without taking the filter body out of the sample line. Where possible,

self-cleaning filters shall be used. Guard filtration shall be in the 0.5 to 1 micron range. The use of paper filtersshall be avoided.

2.3.8 The Supplier shall provide sample vents. They shall be vented to the atmosphere outside and above the

analyzer shelter. Supplier shall provide flame arrestors. Supplier shall provide the Purchaser with the return

pressures of samples.

2.3.9 Copper and copper base alloys shall not be used for any interior metal parts that will be exposed to the

sample stream. In addition, these materials shall not be used for non-process applications where exposed to

the atmosphere, unless the materials are protected.

2.3.10 Full capacity relief valves shall be installed to protect the system components with the discharge into the

vent system, where applicable.

2.3.11 The preferred interconnection between components is by tubing using compression fittings.

2.3.12 Adequate facilities shall be provided to protect against unwanted back flow, over pressure, or safety

hazards.

2.3.13 Appropriate measures shall be taken to prevent plugging of sample lines due to freezing, condensation,

or build-up. Steam connections for steam-out, or rod-out devices shall be provided where plugging is likely to

occur.

2.3.14 The volume of each sample shall be repeatable to 0.1%.

2.3.15 Pressure regulation shall be held within 1% of set pressure.


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2.3.16 Carrier gas flow rate shall be held to ±1/2%.

2.3.17 Threaded connections shall be tapered and conform to ASME B1.20.1.

2.3.18. Installation of pipe shall be in accordance with the applicable portions of ASME B31.3.

2.3.19 Samples shall be transported at the minimum pressure for reliable operation. Excessively high

pressures shall be avoided.

2.3.20 The Supplier shall furnish a manual laboratory sample take-off connection for each sample line at the

sample system. The take-off connections shall be via isolation valves and flexible stainless steel tubing with

tight shutoff quick disconnect fittings installed across the fast loop flow control valve. A support shall be

provided for the sample container.

2.3.21 Variable area flowmeters shall be as follows:

a. Variable area flowmeters shall be the metal tube type except that glass tube enclosed type may be used if

the fluid is air, inert gas or water at operating pressures below 50 psig.

b. When flow rates are lower than can be metered with the metal tube, glass tube enclosed in a heavy duty

gage glass (flat glass type) shall be used.

c. Where space or layout considerations do not allow the use of such gage glass enclosures, proposals to use

the glass tube type with other types of shielding for personnel protection shall be submitted to Purchaser for

approval.

d. End connections smaller than NPS 1/2 shall be internal taper thread connections.

e. Manufacturer’s standard tube and float shall be used where possible with normal flow rates between 60%

and 80% capacity.

f. Meter factor shall be included on the nameplate.

2.3.22 The Supplier shall furnish block valves as follows:

a. A primary block valve for isolating the sample must be installed outside the local cabinet/panel when the

sample system components are mounted inside local cabinets/panels.

b. A block valve and a final sample flowmeter or pressure indicator shall be mounted at the sample outlet to

the analyzer.

c. Cyclic analyzers, e.g. chromatographs, using liquid phase validations samples shall have a ball valve

located close to the analyzer to block the sample flow during the validation analysis cycle to minimize use of

validation sample.

d. Lines containing flammable or toxic material or oxygen located inside shelters or cabinets shall have a

clearly labeled fire-safe ball valve located outside the shelter or local cabinet.


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2.3.23 Unless otherwise specified, provisions shall be made for flushing the sample conditioning system and

analyzer with nitrogen or instrument air prior to disassembly for maintenance. Systems containing

hydrocarbons must use nitrogen. The flushing connection shall be immediately upstream of the fast loop filter.The primary connection to the sample line shall be a three way valve with a second double block and vent three

way valve to isolate the nitrogen/instrument air. If process pressure is higher than utility pressure, a check valve

and removable flexible hose connection shall be provided.

2.3.24 Relief valves shall be provided downstream of pressure reducing valves where required to protect the

analyzer and downstream conditioning system components.

2.4 Analyzer

2.4.1 The oven shall be equipped with independent temperature controls to provide a stable operating

temperature for the analytical columns and detection to assure reproducible component analysis.

2.4.2 The oven shall be protected against overheating due to instrument air failure or malfunction of any kind.

2.4.3 Detector output signal shall be shielded against common mode noise and normal mode noise in addition

to RFI and EMI.

2.4.4 Detector shall be provided with suitable protection to prevent element damage due to loss of carrier gas.

2.4.5 An automatic igniter and hydrogen shutoff shall be incorporated in all flame type detectors to protect

against flame failure. A catalytic air clean-up unit shall be provided in the air supply of all Flame Ionization

Detectors (FID). Flame Photometric Detectors (FPD) shall specify use of zero grade air.

2.4.6 Carrier gas of helium, hydrogen, or nitrogen may be used as required by the measured components.

2.4.7 The Supplier shall provide an option for the following: A gas cylinder manifold with two stage pressure

regulation, inlet and outlet pressure gauges, and low pressure valving shall be provided for each carrier and

calibration gas. High-pressure gas cylinder regulators shall be equipped with a pressure relief valve.

2.4.8 All regulators shall be equipped with stainless steel diaphragms.

2.4.9 The flow rate of the carrier gas shall be adjustable without shutting the system down. The analyzer shall

be equipped with electronic pressure control.

2.4.10 The analyzer shall meet or exceed the following specifications:

a. Reproducibility shall be ±1% of span.

b. Sensitivity shall be ±1/2% of span. (Note that this is not interchangeable with the lower level limit of

detection as specified on the data sheets.)

c. Cycle time shall be as stated on the data sheet. If not as stated, Supplier shall quote shortest possible

cycle time for this analysis.

d. "Column" life shall be a minimum of six months during normal operation.

e. Analyzers shall be approved for use in the specified area classification to a standard that is recognized by

the appropriate local authority. A label providing information on the approval shall be permanently fastened

to the analyzer.


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2.4.11 Flame type detectors shall have flame arrestors in the vent and a local flame ignition switch. The flame

arrestor shall be readily accessible for maintenance purposes.

2.4.12 Intercolumn detectors are to be provided on all gas chromatographs to allow for set-up of heartcut/backflush timing.

2.4.13 The analyzer shall be equipped with the necessary analog and digital input/output circuitry required to

interface with external devices that shall be specified in the individual analyzer Data Sheets. Analog signals

shall be electrically isolated.

2.5 Controller

2.5.1 The chromatograph analyzer and its controller shall be either wall or rack mounted in the analyzer shelter.

The analyzer controller and all associated electrical systems shall be installed in enclosures suitable for the

electrical area classification specified on the Instrument Data Sheets. The preferred method is a purged

enclosure in accordance with NFPA 496.

2.5.2 The analyzer controller shall be microprocessor based, with one controller dedicated to each analyzer.

The Supplier may recommend an alternate configuration if economics are a consideration. All electronic

components shall be suitable for installation in a non-air conditioned, non-heated shelter. All electronic

components shall be conformal coated or suitably protected against trace H2S corrosives, and humidity.

2.5.3 The gas chromatograph systems shall be provided with the necessary modules to allow transmission of

sample composition to the plant Distributed Control System (DCS) system. The Supplier shall provide digital

interface to the plant DCS system. In addition, an alarm shall be provided for each analyzer programmer to

indicate analyzer trouble or failure. Supplier to state in proposal methods of interface to DCS's, such as

Honeywell and Foxboro.

2.5.4 The controller shall be integral with the analyzer.

2.5.5 Manual operation of the analyzer shall be available at both the analyzer and the maintenance workstation.

2.5.6 Loss of power to the controller shall not cause loss of controller memory. Provide details on memory

storage, including type and battery life.

2.5.7 Detector reading shall be automatically zeroed after each component measurement.

2.5.8 An easily accessible set of terminals shall be available at the analyzer face for a chromatogram recorder.

2.5.9 Peaks to be measured must be separated from all interferences so that a few seconds of baseline are

provided on either side. Skimming and dropping tangents are not to be used to establish peak area.

2.5.10 If required, the chromatograph maintenance workstations shall be located in an analyzer room within the

Control Center (See attached Analyzer System Block Diagram). The workstation shall, as a minimum, have the

following capabilities:

a. access all the analyzers on the network or through a separate link connecting all the workstations.

b. start and stop all chromatographs on the network.

c. simultaneous acquisition of real-time chromatographs from several (max. ten) analyzers without degrading

network communication speed.


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d. monitor and modify all chromatograph control parameters such as (but not limited to) oven and other

heating zone temperatures, electronic pressure regulator settings, stream selection valves, column valve

times, peak integration periods and all other analyzer operating tables. All changes shall be downloaded to

the analyzers at the end of the analysis cycle in which changes were made.

e. overlay of stored and real-time chromatograms. Long term, selective chromatogram storage capability is

required.

f. Peak Table modification shall occur directly from peak changes made to a chromatogram. Peak names

shall be transferable to the Table in a similar manner.

g. perform mathematical calculations on raw data and output results to other analyzers and/or the DCS

system.

h. monitor and acknowledge analyzer status and all hardware and software alarms.

i. enable/dis-enable reporting of data to any output device.

j. data shall be readily transferable to and from each analyzer.

k. capability to generate analyzer maintenance reports and performance service factors.

l. initiate auto validation and calibration of analyzers and transmit data to the DCS.

m. capability to perform statistical trending of analyzer variables and measured compositional data.

n. a menu driven, self prompting, user friendly approach is required with regards to setting up the analyzer.

o. analyzer parameters and process data shall be readily transferable to commercially available softwareprograms such as MS EXCEL.

p. external connections to other LANs and direct Supplier support capability (via modem) shall be

incorporated.

q. all analyzer operating and maintenance manuals and spare parts list shall either be resident in the

workstation or available for loading into the workstation from a disc.

r. data link to the DCS system shall continue to remain operational in the event of workstation failure.

3. INSPECTION AND TESTING

3.1 General

3.1.1 The Supplier shall bear all responsibility for establishing quality control and expediting programs to ensure

that the analyzer systems leave their manufacturing facility complete in a fully operational and calibrated

condition.

3.1.2 All analyzer components, tubing, sample systems and utility piping shall be leak tested at the specified

design pressure. Maximum permissible leakage rates are as follows:

a. Gas Systems to be tested with helium: 5 percent change per hour of the specified design pressure

b. Liquid Systems: No visible leakage


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3.1.3 All inspections and testing (including recordings) shall be documented in writing by the Supplier and

submitted to the Purchaser during the Factory Acceptance Test (FAT). All costs associated with inspection and

customer witness testing shall be included in the Supplier's quoted price for the analyzer systems.

3.1.4 The complete analyzer system(s) shall be calibrated and set up to verify the correct functioning of the

supplied equipment using certified calibration samples provided by the Supplier. The test samples shall be at

the conditions and of the composition specified by the Purchaser. A minimum of two unique gases shall be

used for system checkout. A continuous operational test (Reproducibility Run) shall be conducted for each

analyzer for a minimum of 24 hours. Costs for the above calibration tests shall be included in the Supplier's

quoted price. These tests may or may not be witnessed by the Purchaser.

3.1.5 After the Supplier tests are completed, two weeks advance notice of the date and time of the FAT shall be

given to the Purchaser.

3.1.6 Final inspection and test (which may or may not be a part of FAT) shall be as follows:

a. All items furnished by the Supplier shall be checked against the final approved drawings and bill of

materials.

b. The entire integrated system shall be air leak-checked unless otherwise specified in the individual analyzer

data sheets.

c. All dimensions shall be checked against the final approved drawings.

3.1.7 The Supplier shall provide for review at the FAT the following data:

a. Linearity and calibration data to check linearity of detectors within 1% of stated value.

b. Chromatograms of all calibration standards and samples analyzed annotated to show sequence ofoperation and identification of all peaks.

c. All program tables and output/input tables.

d. Alarm list

e. Reproducibility run (24 hour)

f. Final valve and oven layout

g. Set up data and gas chromatograph star-up procedure

h. Baseline drift data

3.1.8 All fabrication, materials, and packaging shall be subject to inspection by the Purchaser, or by an

authorized agent of the Purchaser. The latest drawings and bills of material of the items shall be available to the

Purchaser's inspector or agent at the time of the inspection.

3.2 Nameplate Identification

Analyzers shall have the following information on a nameplate permanently fastened to the analyzer:

a. Equipment identification number.

b. Pressure rating of pressure holding parts.


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c. Manufacturer's name, model, serial number, operating range, output signal and range, supply voltage,

frequency, and material of parts exposed to process fluids.

d. Electrical area classification for which analyzer is suitable.

4. DOCUMENTATION

4.1 Manuals

The Supplier shall include in his quotation the cost of one set of manuals and certified "As Built" drawings for the

supplied gas chromatograph systems. Instruction and maintenance manuals shall be provided for all supplied

equipment. Plan drawings shall be provided for equipment layout, sample and utility piping, and electrical.

Interconnecting cable schedules and wiring schematics for all supplied power and signal wiring shall be

provided. All other drawings required to build and document the analyzer systems shall be provided. The

Supplier shall quote cost for each additional set of all applicable documentation.

4.2 Radioactive Sources

For analyzers containing radioactive or ionizing sources, all details of the source shall be forwarded to the

Purchaser within 4 weeks of order placement to allow site safety and local operating permits to be obtained.

4.3 Shipping Documentation

Preliminary documentation and all software which is required to install and start-up the analyzer shall be

shipped with the analyzer.

4.4 Supplier Data Requirements

Additional documentation requirements shown in attached KBR Supplier Data Requirements (SDR) shall be

adhered to in the Supplier's proposal.

4.5 Spare Parts

Supplier shall include in proposal recommended spare parts for one year of operation, plus start-

up/commissioning spare parts. The start-up and one year spare parts shall be provided in two, separate lists.

5. SUPPLIER SUPPORT

5.1 Training

Supplier shall include documentation on the recommended training classes for the end user. Pricing andschedule shall be included in the proposal.

5.2 Field Support

Supplier to include recommended start-up support for the proposed system. The costs should be itemized.