Chevron Specification ICM-MS-4362-B

FABRICATION OF PROCESS ANALYZER SYSTEMS

Commented Copy - Not for Vendor/Contractor Distribution

SPECIFICATION ICM MS-4362-B

FABRICATION OF PROCESS ANALYZER SYSTEMS

NOTE: This document is the "Commented" version of Specification CIV-

EG-4047-B. The comments, based on Company experience, provide
background for the requirements stated in the Specification. These
comments are for Company use only, not for distribution to Vendors or
Contractors.
Electronic copies of the Company’s MS/EG Specifications and the
accompanying data sheets and data sheet guides are available by E-mail
and from CRTC’s Technical Standards website. To access the files over
Chevron’s Intranet, use the following website address:
http://techstds.rrc.chevron.com/tech_standards
To receive electronic files by E-mail, phone (510) 242-7241 or send E-mail
to TECHSTDS (“CRTC Tech Standards” in the Global Address List), or fax
your request to (510) 242-2157.

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FABRICATION OF PROCESS ANALYZER SYSTEMS
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CONTENTS
1.0 SCOPE................................................................................................................................................... 3

2.0 DEFINITIONS ..................................................................................................................................... 3

3.0 FABRICATOR'S RESPONSIBILITY ............................................................................................. 4

4.0 SCHEDULE.......................................................................................................................................... 4

5.0 COMPANY STANDARDS, PRACTICES, APPROVALS ............................................................ 5

6.0 SUPPLEMENTARY INFORMATION FROM COMPANY........................................................ 6

7.0 DRAWING REQUIREMENTS......................................................................................................... 7

8.0 ENCLOSURE DESIGN REQUIREMENTS.................................................................................... 8

9.0 DESIGN AND FABRICATION REQUIREMENTS.................................................................... 14

10.0 REQUIREMENTS FOR FINAL APPROVAL BY COMPANY................................................ 20

11.0 SHIPPING REQUIREMENTS........................................................................................................ 21

12.0 DOCUMENTATION REQUIRED ................................................................................................. 22

13.0 FIELD WORK REQUIREMENTS................................................................................................. 23

14.0 REFERENCES................................................................................................................................... 23

15.0 ATTACHMENTS .............................................................................................................................. 28

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FABRICATION OF PROCESS ANALYZER SYSTEMS
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1.0 SCOPE

This specification covers the design, fabrication, testing, and shipment of process analyzer systems.
These tasks shall be performed by an analyzer systems fabricator hereafter referred to as the
Fabricator. A list of analyzers covered in this specification is included in Section 15.0.

2.0 DEFINITIONS

2.1 A process analyzer system consists of one or more commercial analyzers with custom designed
sample conditioning systems. The sample conditioning systems are installed in an enclosure
that contains all the facilities needed to calibrate and operate the analyzers.

2.2 The enclosure may be either a totally enclosed house, a three-sided shelter, a free-standing
cabinet or a rack. The details of construction for each of these are covered in Section 8.0 of this
specification.

2.3 Environmental Conditions (These conditions should match those defined in the analyzer
enclosure checkoff list.)

2.3.1 Climatic Conditions

Winter Design Temperature, Minimum: ____________________

Summer Design Temperature, Maximum: ___________________

Relative Humidity: Minimum _________ Maximum ___________

Design Rainfall, Maximum: ___________________________

Wind Velocity, Maximum: ____________________________

Plant Elevation Above Sea Level: ________________________

Note: Identify any special design conditions such as seismic zone or snow loads
(if applicable).
2.3.2 Electrical Area Classification

Class ______ Group _______ Division _______ Other ______

2.3.3 The environment inside the analyzer house shall be:

Temperature: ___________________

Relative humidity: ________________

Air Contaminants: (If applicable) ___________________

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FABRICATION OF PROCESS ANALYZER SYSTEMS
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Electrical Classification:

Class ______ Group _______ Division _______ Other ______

3.0 FABRICATOR'S RESPONSIBILITY

The purpose of this section is to clearly define the responsibilities of the Fabricator.

Comment 3.0 This section is intended to avoid questions regarding whether the Fabricator or the
analyzer Vendor has responsibility for the guarantee of a properly working and designed analyzer
system. The Fabricator's responsibilities shall covet the applicable sections in 3.0..

3.1 Provide design documents for Company approval in accordance with Sections 3.0 and 10.0 of
this specification.

3.2 Procure analyzers in accordance with the approved Analyzer Specification Sheets.

3.3 Fabricate analyzer systems in accordance with the approved designs and this specification.

3.4 Guarantee that the analyzer systems and systems designed will perform the functions specified.

3.5 Assist the Company with factory inspection.

3.6 Prepare the analyzer systems for shipping to the plant site.

3.7 Prepare certified drawings and analyzer system manuals.

3.8 The Fabricator shall provide assistance for installation, inspection, precommissioning testing,
startup, and training (as required).

4.0 SCHEDULE

The Fabricator shall submit, with the bid, a preliminary schedule of the following events for each
analyzer system in order to provide verification of the ability to meet the required shipping date:
1. Engineering designs ready for approval (The designs shall be presented to the Company for
approval in scheduled review meetings.)
2. Orders placed for equipment and material
3. Fabrication of analyzer system start and finish
4. Factory inspection and test
5. Shipment date of analyzer systems
6. Shipment of analyzer systems manuals
7. Field inspection, testing, and training
Upon award of the contract, the Fabricator shall provide the Company with a firm schedule.

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FABRICATION OF PROCESS ANALYZER SYSTEMS
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5.0 COMPANY STANDARDS, PRACTICES, APPROVALS

5.1 Standards and Practices

The analyzer systems shall conform to all applicable standards and codes including those listed
below of this Specification:

5.1.1 National Electrical Manufacturers Association (NEMA) standard

5.1.2 National Electric Code (NEC)

5.1.3 American Institute of Steel Construction (AISC) specifications

5.1.4 Metal Building Manufacturer's Association regulations

5.1.5 Uniform Building Code (UBC)

5.1.6 American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code,
Section IX

5.1.7 American Society for Testing and Materials (ASTM) test methods (D 638, D 790, D
256, D 2583, D 570)

5.1.8 National Fire Protection Association

5.1.9 All other national, state and local codes

5.2 Approvals

5.2.1 Items for which Company approval or agreement is required in writing shall include,
but not be limited to, the following list:
1. The completed Analyzer Specification Sheet for each analyzer
2. An outline and dimension drawing, plan and elevation, for each analyzer
system
3. Sample system schematic diagram with an equipment list for each analyzer
system
4. Sample system layout drawing for each analyzer system
5. Electrical wiring diagram (with equipment list) showing all signal and power
wiring
6. Structural detail drawings for the enclosure showing the connection of
structural panels, roof and frame
7. Support (such as unistrut, post or pedestal) for the rack and panel or cabinet
mounted on the panel. Legs for the freestanding cabinet
8. Details of attachment to either a concrete slab or a steel structure (as required)
9. Final inspection of the analyzer system to ensure that the fabrication conforms
to the specification
10. Witnessing of the factory test
11. Time schedule for fabrication, testing, and shipping of each analyzer system

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5.2.2 Within 10 working days of receipt of the documents, the Company shall advise the
Fabricator of comments or approval. The Company's failure to reply within 10 days
shall be deemed as approval of said documents.

5.2.3 The Company review and approval (or approval by default) shall in no way relieve the
Fabricator of their responsibilities, obligations, or liabilities.

5.2.4 The Company shall be given a reproducible copy of each approved document. The
Fabricator shall notify the Company if any factory modifications are made to the
approved design. If modifications are made, the Fabricator shall issue a revised
document to the Company.

5.2.5 Analyzer system shall not be shipped from the factory until written approval is
obtained from the Company.

6.0 SUPPLEMENTARY INFORMATION FROM COMPANY

The Company shall provide the following information:

6.1 A list of acceptable analyzers - types, makes, models.

Comment 6.1 Acceptable analyzers should be determined by the location where they will be
installed. CRTC analyzer specialists can be used as a resource to determine past analyzer
performance throughout the Company and the industry. Also refer to Section 800 of the
Instrumentation and Control Manual.

6.2 A list of acceptable analyzer sample system components and additional parts.

Comment 6.2 A list of acceptable analyzer system components can be formed in consultation
with local maintenance personnel and consulting with analyzer specialists. It should be
included in Section 15.0 of this specification. This list is by no means all inclusive. Allow the
Fabricator to propose alternatives subject to Company approval.

6.3 An enclosure check-off sheet for each enclosure.

6.4 A preliminary Analyzer Specification Sheet for each process analyzer with the available
information filled in.

6.5 Number of systems manuals required.

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FABRICATION OF PROCESS ANALYZER SYSTEMS
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7.0 DRAWING REQUIREMENTS

7.1 Outline and Dimension Drawing of Analyzer System

Provide an outline and dimension drawing for a physical description of each analyzer system.
It shall include, but not be limited to, the following:
1. Plan view and exterior elevation views
2. Dimensioned location of analyzers and major equipment
3. Dimensioned location of field connections for utilities, sewers, sample lines, electrical
power, and signals
4. Critical clearance requirements (for example, clearance in front of electrical panels).
7.2 Sample System Schematic Diagram

7.2.1 Provide a schematic diagram for each analyzer system showing the design detail of the
sample line system and sample conditioning module. The schematic should be as close
to the actual layout as reasonably possible. It shall include, but not be limited to, the
following:
1. Recommendation for sample probe location and physical design
2. Location and capacity of a sample cooler when one is required (The cooling
media shall be specified.)
3. Length and diameter of the sample line, critical routing and slope (The
requirements for heat tracing and insulation shall also be specified.)
4. Sample time lag from sample point to analyzer with explanation of basis
5. Other auxiliaries needed on the sample line or fast loop such as flow meters,
temperature and pressure indicators, sample pumps and knockout pots
6. The type of enclosure used for the sample conditioning module (The location
of the enclosure shall be shown on the diagram. Heater or cooler requirements
shall be specified.)
7. Each component used in the sample conditioning module such as selector
valves, liquid traps, filters, dryers, vaporizers, pressure regulators, flow meters,
pressure gages, temperature indicators, heaters and coolers designated by a
number
8. The interconnecting tubing used in the sample conditioning module with notes
covering the size, material, and critical routing
9. Methods for removal of impurities and condensate from gas sample (or gases
from liquid sample)
10. Operating conditions of sample conditioning system including flow rates,
temperatures and pressures
11. Facilities for manual or automatic calibration including valves required to
prevent cross contamination of process sample and calibration standards
12. Required utilities
13. Electrical power including voltage and current requirements, voltage
frequency, and noise tolerances

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14. Signals transmitted to control center including, analyzer measurements, contact

outputs for sample stream identity, limit alarms, and measurement validity
alarms
15. A list of the analyzer validity checks needed to establish valid measurement
data
7.2.2 All equipment used in the sample system shall be provided with a complete description
on an accompanying equipment list.

7.3 Electrical Wiring Diagram

7.3.1 Provide an AC and DC electrical wiring diagram that shall include the following:
1. All electrical equipment and components used in the analyzer system (Show
sizes and ratings for all electrical equipment.)
2. Terminal strips for analyzers and instrumentation (Show terminations for
electrical power and signal wires.)
3. Terminal strips for lighting and HVAC equipment (Show terminations for
electrical power and controls.)
4. Circuit breakers, distribution panels and transformers (Show terminations for
electrical power.)
5. All interconnecting electrical and signal wiring with wire size and cable
designation
6. Electrical grounding
7. Voltage levels
8. Circuit breaker ratings
9. All terminal strips shall be numbered
7.3.2 A complete description, including a list of the suppliers, of all electrical equipment and
components used in the analyzer system shall be provided on an accompanying
equipment list.

8.0 ENCLOSURE DESIGN REQUIREMENTS

This specification covers the requirements for the design and construction of a totally enclosed house
for process analyzers.

8.1 Standards And Practices

The house shall conform to all applicable standards and codes including those listed in Section
14.0 of this specification to ensure that the following are met:
1. Company standards of design, construction, and safety.
2. All national, state, and local codes including, but not limited to, the latest versions of
the following:
a. Uniform Building Code (UBC)
b. AISC Design Manual
c. Regulations of Metal Building Manufacturer's Association

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FABRICATION OF PROCESS ANALYZER SYSTEMS
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d. OSHA
e. Chevron CIV-EG-398, Steel Fabrication (Standard Specification)
f. Chevron Section 100, CIV (Civil and Structural Manual)
8.2 Supplemental Information

The Company or the Contractor designated by the Company will attach the following
information:

8.2.1 A sketch of the house showing the size and location of the doors and the location and
size of cutouts for HVAC equipment.

8.2.2 An estimate of the location of analyzers and all other equipment to be mounted on the
walls of the house.

8.3 Design And Construction Requirements - Analyzer House

8.3.1 The size of the house will be specified by the Company (Section 3.1). The minimum
inside ceiling clearance shall be 96 inches, measured from the top of the base channel.
The minimum size house shall be 6 by 8 feet and meet NEC requirements for clearance
around electrical equipment.

8.3.2 The structure shall have sufficient strength and rigidity to withstand static and dynamic
forces from the following loads without structural deformation or fatigue failure:
1. Loads on walls produced by analyzers, instruments, equipment panels and
cabinets, electrical equipment and HVAC equipment
2. Acceleration and vibrational loads produced during shipment of the house to
the plant site after the equipment described in Section 3.2 has been installed
3. Lifting and moving the fully loaded house at the plant site
4. A live load applied (in accordance with UBC, the Uniform Building Code):
a. On the roof of 20 psf or 1000 pounds concentrated load
b. On the floor of 100 psf or 1000 pounds concentrated load
5. Wind and seismic loads in accordance with UBC and Section 100 of the Civil
and Structural.
8.3.3 The floor of the house shall be:
1. A concrete slab when installed at grade (Provided by others)
2. Steel plate with nonskid coating, when installed on an elevated platform
(Provided with house)
8.3.4 The walls and roof shall be fabricated from interlocking panels of galvanized sheet
steel, 18 gage or thicker. The panel width shall be a standard size, typically 16 inches.
For enclosures fabricated from fiberglass or other non-metallic materials they should
meet the following specifications:

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Physical Property Min. Requirement ASTM Test Method

Tensile Strength 14,000 psi D 638

Flexural strength 25,000 psi D 790

Flexural modules 1.0 x 106 psi D 790

Impact, Notched,Izod 15 Ft-lb/In D 256

Barcol hardness 40 (Average) D 2583

Water absorption (24 hours) 0.1 % D 570

Fiberglass-reinforced polymer constructions shall have smooth, gel-coated surface

without exposed glass fibers. Color shall be molded in. The materials shall be treated
for ultra-violet protection. Only corrosion-resistant, fire-retardant type materials are
acceptable.

8.3.5 The roof shall be flat with slope of not less than 1/8 inch per foot. The roof shall extend
a minimum of 8 to 12 inches beyond the walls all around.

8.3.6 All exposed fasteners should be made of stainless steel.

8.3.7 All material shall be new, clean and straight. Prior to construction, all surfaces shall be
cleaned to white metal. The surfaces shall be free of oil, wax, grease, scale, and dirt for
welding and for proper adhesion of finish coating.

8.3.8 Cylinder racks shall be provided for required gas cylinders and will include space for
20% spares.

8.3.9 The materials of construction shall be noncombustible and corrosion resistant. Copper
alloy is not permitted in locations exposed to the plant environment. All carbon steel
must be galvanized. Any damage of the galvanizing integrity shall be repaired with a
zinc-rich coating.

8.3.10 Leak-proof construction is required. For example, the closure between the walls and
roof shall have flanged construction. Butt closures sealed with caulking are not
acceptable. Passages through the wall or roof for HVAC equipment shall be
constructed with flanged sheet metal trim to provide a seal. A vapor barrier for the
insulation is required.

8.3.11 For houses a minimum of one door and an emergency escape hatch shall be provided
for buildings 6 ft by 8 ft. For buildings larger than that two doors should be provided.
Doors should open outward and be equipped with panic bars on the inside. Standard
doors shall be used that are constructed of 16-gage sheet steel continuously welded to
edge channels. The cores shall be fire-resistant resin bonded to the interior sheetmetal

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FABRICATION OF PROCESS ANALYZER SYSTEMS
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surface. Reinforcing plates of 12-gage steel shall be welded to the door for hardware
mounting. Each door shall have a sealed window with wire-reinforced safety glass or
Lexan. The door frames shall be of welded steel construction. The doors shall be
mounted with a minimum of three hinges. There shall be one common key to all
analyzer houses in the plan.

8.3.12 Provide extenders on the channel base with lifting eyes to permit lifting the fully
loaded house at the construction site. Cable spreaders shall also be provided to permit
a four-point lift with a single crane hook without damaging the house. Extenders and
spreaders shall be shipped with the house. The size of the house shall conform to laws
regulating the dimensions of structures transported on public highways.

8.4 Three-Sided Shelter

The shelter shall be a rigid, free-standing, three-sided structure with a roof, and shall be
skid-mounted.

8.4.1 Unless use of non-metallic materials is specified in the enclosure checkoff sheet or by
Company project instructions, the shelter shall be fabricated from galvanized steel.

8.4.2 The steel base shall be fabricated from 8-inch channel (or equivalent rigidity) per
Specification CIV-EG-398.

8.4.3 A welded steel vertical dome is desirable but not required. Welding shall be performed
per ASME Boiler and Pressure Vessel Code, Section IX. Joint surfaces shall be free
from fins and tears. Welds shall be provided so as to carry the entire stress for which
the connection is designed. Bolts in combination with welds shall not be considered as
sharing the stress.

8.4.4 Zinc coat all structural members using hot dipped galvanize process per CIV-EG-398.

8.4.5 The walls and roof shall be fabricated from interlocking panels of galvanized sheet
steel, 18 gage or thicker. The panel width shall be a standard size, typically 16 inches.
Leak-proof construction is required for wall and roof panels. For example, the closure
between the walls and roof shall have flanged construction. Butt closures sealed with
caulking are not acceptable.

8.4.6 The roof shall be flat with slope of not less than 1/2 inch per foot. The roof over hang
shall extend a minimum of 12 inches beyond the front (i.e., the open side) and the back.

8.4.7 Fasteners for securing sheet metal panels to the frame or to one another shall use bolts
with nuts (1/4" minimum). Self-tapping sheet metal screws are not acceptable.
Fasteners shall be made of stainless steel.

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8.4.8 The size of the shelter will be specified by the Company in the analyzer enclosure
checkoff sheet. The minimum inside clearance shall be 96 inches, measured from the
bottom of the base channel (or from the joint of the frame and floor for the angle iron
frame with corrugated fiberglass panel design). The minimum enclosure size shall be 6
by 8 feet.

8.4.9 For channel based design, provide wind relief vents on the rear side of the shelter.
Openings between roof and wall panels, if so designed, shall provide adequate
protection for analyzers and equipment from rain storms.

8.4.10 For shelters fabricated from angle iron frame with corrugated fiberglass panel,
openings between wall panels and roof (and openings between wall panels and "floor"-
if needed) shall be designed to provide adequate ventilation as well as protection for
the analyzers and equipment from rain storm.

8.5 Free-standing Rack

8.5.1 The term rack in this Specification refers to a metal rack with one or more metal plates
for the purpose of mounting small size analyzers, sample conditioning modules and
other instruments.

8.5.2 The rack shall be fabricated from steel and shall be of bolted unistrut (or equal)
construction. All steel parts shall be hot dipped galvanized.

8.5.3 The upper edge of the rack should be no higher than 66 inches (typical) from the
foundation or footing for easy access.

8.5.4 Unless a different type of material is specified in the Analyzer Enclosure Data Sheet
DS-4362, or by Company project instructions, the plate(s) shall be fabricated from 1/4
inch Alloy 6061-T65 aluminum and may require painting if specified in the Data Sheet.

8.5.5 A rain shield or sun shield may be required. The need for the shield should be either
recommended by the Fabricator or specified by the Company in the Data Sheet.

8.6 Cabinet

8.6.1 The term cabinet in this Specification refers to one of the following designs:

8.6.1.1 One or more cabinet enclosures flush mounted on a metal plate supported by
a frame, or a pipe, or a pedestal.

8.6.1.2 A free-standing cabinet enclosure usually supported by its legs ("floor

stands").

8.6.2 Unless a different type of material is specified in the Analyzer Enclosure Data Sheet
DS-4362, or by Company project instructions, the plate shall be fabricated from 1/4
inch Alloy 6061-T65 aluminum and shall be painted (Section 4.0).

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8.6.3 If a rack is used to support the cabinet and plate, it shall be fabricated from materials
equivalent to that for the plate and shall be of bolted unistrut (or equal) construction.
The upper edge of the rack should be no higher than 66 inches (typical) from the
foundation or footing for easy access.

8.7 Materials of Construction

8.7.1 The free-standing cabinet enclosure shall be fabricated from steel, stainless steel,
fiberglass, or aluminum based on the Analyzer Enclosure Data Sheet. Two doors shall
be provided complete with hardware and oil-resistant gaskets. The type of door closure
should also be specified.

8.7.2 The small size cabinet which is flush-mounted on a plate may be fabricated from the
materials specified on the the Analyzer Enclosure Data Sheet.

8.7.3 For metallic type cabinets, all exterior hardware (such as clamps, clamp screws, hinge
pins, etc.) shall be made of 304 stainless steel. All seams shall be continuously welded.

8.7.4 Non-metallic type cabinet shall be fabricated from fire-retardant materials.

Fiberglass-reinforced materials should meet Underwriters Laboratories (UL) 94V-0
flammability rating, or should be less than 25 per ASTM Test Method E 84, or equal.

8.8 Miscellaneous

8.8.1 Purged enclosures as per NFPA 496 are preferred for all designs.

8.8.2 Sub-panel design will be specified in the Analyzer Enclosure Data Sheet.

8.8.3 A rain shield or sun shield may be required for a flush mounted cabinet on a plate and
rack. The need for such a shield should be either recommended by the Fabricator or
specified by the Company in the Analyzer Enclosure Data Sheet.

8.8.4 Provide cutouts as required for air-conditioning unit or purge connection.

8.8.5 Provide window kit or window(s) as needed. The Analyzer Enclosure Data Sheet will
specifically call for window(s). Fabricator shall indicate on the drawing submitted to
the Company the window(s) on the cabinet.

8.8.6 Provide enclosure stabilizers (legs) for the free-standing cabinet enclosure. The
stabilizers are used to prevent injury to workers while working on the cabinet being
bolted.

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9.0 DESIGN AND FABRICATION REQUIREMENTS

9.1 Sample Line System

The sample line system shall be functionally designed by the Fabricator, but purchased and
installed at the plant site by others.

9.1.1 Sample probes shall be used where needed, to obtain a clean and representative sample
or to avoid sample delay. If a sample probe is used, the length of the probe shall be
sized so that the probe opening is in the center 1/3 of the pipe. It may be necessary to
fit a 1/4-inch tube inside a large diameter pipe stub to provide the right combination of
minimum sample lag time and sufficient stiffness of the probe for hydrodynamic
stability. Probes should only be used on lines larger than 2". Also, the 1/4" tubing
through a packing gland is not acceptable. Only a flanged thermowell is acceptable for
a sample point with a probe.

9.1.2 Coolers will be designed to prevent plugging of the cooling media and to allow for a
blowdown of the cooler body itself. Materials of construction should be capable of
withstanding the full temperature of the sample. If cooling tower water is required as
cooling media a differential pressure switch should be proposed to sense plugging of
the filter.

9.1.3 Sample bypass loops shall be provided for each sample system, except for close-
coupled type installations that meet sample lag requirements. The lines shall be 316 SS
tubing with the size determined by the application unless otherwise specified by the
Company (e.g., Teflon for certain H2S applications). Lower sample flow rates may be
approved by the Company for highly viscous materials or situations where pressure
drop is excessive. A throttle valve and a flow meter shall be provided and mounted on
a plate or a box mounted on the exterior wall of the analyzer enclosure as part of the
sample conditioning module. The total sample lag from the sample point to the
analyzer shall not exceed 1 minute.

An armored-type flow meter shall be used in the fast loop piping where hazardous or
toxic materials are involved or sample source pressure exceeds 150 psig. Pressure
gages shall be included for analyzer inlet, source, and return line pressure indication. A
flow meter with a needle valve shall also be included in the analyzer bypass stream and
in the sample line to the analyzer. Additional pressure gages shall be provided for
setting any pressure reducing valve or regulator installed in the sample system.
Wherever possible, sample system bypass and analyzer effluent shall be directed back
into the slip-stream for return to the process line.

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9.2 Sample Conditioning Module

9.2.1 The sample conditioning module shall be mounted in a cabinet or on a plate as

described in Section 9.1 of this specification and located adjacent to the analyzer on the
outside wall of the enclosure.

9.2.2 The tubing and components shall be made of corrosion-resistant materials, such as 316
SS, Teflon, Kynar, or PVC, and shall be suitable for each particular application. Rigid
metal is preferred. Polymers are acceptable only in very specific applications.

9.2.3 The tubing and components including the analyzer flow cell shall be configured so they
will not trap gas (for liquid samples) or trap liquid (for gas samples). Liquid samples
systems should include a method to drain the system to a safe place.

9.2.4 All components and interconnecting tubing shall be visible from the front of the panel
or cabinet. Tubing shall not be run through or behind the panel or a panel component
for the sake of appearance or space requirements. Tubing shall not be run behind a
component.. In all cases, the flow path shall be easily traceable from the front side.
All equipment and components shall be accessible and separately removable. There
shall be adequate clearance for servicing components.

9.2.5 Tubing and components on the sample conditioning panel shall not be insulated as this
would obscure their configuration.

9.2.6 Solenoid valves shall be used on pure, clean, nonfouling fluids only. Otherwise, use
air-operated ball valves. The use of air-operated solenoids should be considered in the
high-temperature environment.

9.2.7 Multiple streams and calibration standards shall be isolated from one another by
positive methods such as pressure control, double block and bleed valves, or other
combinations.

9.2.8 Armored rotameters are acceptable for flow indication on fast sample loops. Armored-
type rotameters can be used in the fast loop where hazardous or toxic materials are
involved or the sample source pressure exceeds 150 psig. They can also be used in the
sample system itself where system pressure requires. Glass tube rotameters should have
protection from accidental impact. Mounting in a sample conditioning system box is
acceptable.

9.2.9 Flow, pressure, and temperature instruments shall be sized for mid-range indication.
The units for these instruments shall be: pressure gages, psig; thermometers, deg F; gas
flow meters, cc/min. or SCFH; liquid flow meters, cc/min. or GPM.

9.2.10 Where possible, sample system bypass and analyzer effluent shall be directed back into
the slip-stream downstream of the throttle valve for return to the process line.

9.2.11 All wiring shall be run-in conduit, cable tray, or PANDUIT (for GP enclosures).

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9.2.12 Analyzer electronics shall not be mounted in a sample conditioning system.

9.2.13 Metal or plastic tags shall be installed on all indicators, meters, valves, regulators,
switches, and other operative devices on the sample system. The tags shall identify the
function and the instrument number shown on the schematic diagram. The tags shall be
surface-mounted or attached with 12-gage SS wire.

9.2.14 Sample conditioning systems should be mounted outside the analyzer shelter or
enclosure. Only in the case of a non-hazardous sample or by special approval from
Chevron shall it be mounted inside. Weather covers shall be provided over exterior
sample conditioning modules.

9.2.15 Filters, pumps, and other equipment subject to leakage or frequent dismantling shall be
located outside the analyzer enclosure. For dirty liquid samples, dual filters in parallel
shall be used with differential pressure gages to indicate pressure drop, and isolation
valves shall be used for easy replacement of filter and filter elements.

9.2.16 All piping and tubing shall be installed in the factory. No field work shall be necessary
inside the enclosure. Connections to the field shall be provided on the exterior wall of
the enclosure. Bulkhead connectors shall be used, 50% space for extra connectors shall
be provided.

9.2.17 All heat tracing and insulation of piping and tubing shall be installed at the factory.

9.2.18 Tube fittings shall be Swagelok or facility-approved equivalent.

9.3 Calibration System and Carrier Gases

9.3.1 Each analyzer shall be provided with a means for verifying the calibration accuracy
unless otherwise approved by the Company. This shall be accomplished with zero
gas/liquid and/or span gas/liquid. Any special calibration devices or techniques used as
an alternative shall be approved by the Company.

9.3.2 The Fabricator shall provide the bottled calibration gases and/or liquids and carrier
gases as needed for the factory test. Brass, two-stage regulators shall be used on high-
pressure carrier, utility, and noncorrosive hydrocarbon gases. Stainless steel regulators
shall be used on corrosive gases. Standards containing acetylenes or butadiene shall
not contact copper alloys. Regulators shall be shipped separately from the cylinders.
The cylinder regulators shall be connected to the sample system using flexible, steel-
covered hose.

9.3.3 The calibration standards to be used for routine operation shall be specified by the
Fabricator. The Company will supply gas cylinders for continuing plant operation
following successful commissioning.

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9.3.4 Regulators and tubing shall be installed for spare gas cylinders whenever a loss of gas
would impair analyzer performance. For example, spare gas cylinders will be needed
for chromatograph carrier gas, air and hydrogen for a flame ionization detector, and for
gas standards used with an automatic calibration accessory. The spare regulators shall
be set to "cut in" when the primary cylinder runs out of gas.

9.3.5 All cylinder gases and liquid standards shall be purchased from the local Company
approved supplier. Cylinder size shall be determined by the application. 200 cubic ft.
size is preferred where pressure and composition allow.

9.3.6 Cylinders shall be located on the outside wall of the analyzer houses. The analyzers
shall share cylinders of calibration standards where possible. The Fabricator shall
define the quantity needed to provide 6 months between refills. The standard should be
representative of normal stream conditions. Otherwise, more than one standard shall
be purchased.

9.3.7 Liquid standard cylinders shall be pressurized by a helium cylinder dedicated to that
service and not permanently tubed to more than one standard. Constant pressure
cylinders can be used to supply standards derived from the process where the sample is
representative and there are economic incentives to do so.

All liquid standard cylinders shall be pressure rated for 200 psig minimum. They shall
be tagged as to:
1. Contents
2. Pressure rating
3. Shipping pressure
4. Property of Company or not
5. Tare and gross weight of standard
6. Fill date
9.4 Electrical Signals

9.4.1 All analog/digital signal transmitters, whether they are discrete transmitters or built into
analyzers, shall have two terminals that are isolated from ground and from other
transmitters. A shielded wire pair shall be run from each transmitter. There are to be
no common lines. Analog and digital signals shall be segregated in separate shielded
cables.

9.4.2 Digital signal transmitters shall be RS-232C or RS-485 modems with 20 mA (24-volt),
current loops capable of a 5000-foot range on a twisted-wire pair. Any alternatives
should be clearly noted in the specification.

9.4.3 Each analyzer system shall have status contacts or software-driven alarm indications to
define:
1. Loss of sample flow to the analyzer or in the fast loop
2. Validity of the analyzer measurement data
3. Status of the automatic calibration system

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4. Other conditions required by the particular application.

For chromatographs the alarm/status indications include:
1. Carrier pressure failure
2. Oven purge pressure failure
3. Electronics purge flow failure
4. Electronic door interlock override
5. Excessive baseline offset or autozero out of range
6. Oven temperature out of range and/or unstable
7. Total chromatogram area outside of application specific limits
These can be combined into one common contact for the control room as long as there
is facility to define the problem at the analyzers.

9.4.4 Status contacts shall be connected to the control center or to a local annunciator with a
common contact to the control center as directed by the Company.

9.4.5 Validity checks specified for control applications can include alarm/status indications
from each analyzer or from a central analyzer management system.

9.4.6 Each analyzer shall be provided with a local readout of the measurement signal. If it is
an environmental monitoring system this readout should include both the raw and
corrected readout.

9.4.7 Signal wires from analyzers shall be run in conduit to a signal junction box located on
the outside wall of the enclosure. All wiring between the analyzers and terminal strips
in the junction box shall be installed in the factory. Signal and electrical power wires
shall be run in separate conduit and terminated in separate junction boxes.

9.5 Electrical Power and Lighting

9.5.1 Electrical equipment including analyzers, instrumentation, sample system equipment,

lighting, air-conditioning and heaters shall comply with all applicable codes and
standards for the required electrical classification.

9.5.2 Working space around all electrical equipment shall conform to Article 110-16 of the
National Electrical Code and all other applicable requirements. In addition, the
clearance in front of electrical terminations shall be 3 feet or greater.

9.5.3 Each unit of equipment (analyzers, pumps and the HVAC unit) shall be equipped with
a local electrical disconnect switch (with provisions for locking) for local shutdown
and isolation of electrical service. As a substitute, a power distribution panel with a
separate circuit for each major device and a lockout facility would be acceptable.

9.5.4 Electrical power wires shall be run in conduit to an electrical power junction box
located on the wall of the enclosure. All wiring between equipment and terminal strips
in the junction box shall be installed in the factory. Electrical power and signal wires

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shall be run in separate conduit and terminated in separate junction boxes. All conduit
shall be installed in a workmanlike manner with adequate clamp or hanger supports to
ensure proper alignment. The conduit shall be mounted in locations that will not
interfere with maintenance or removal of any analyzer or equipment in the enclosures.
All joints shall be made up wrench-tight with at least five full threads engaged. A
3/4-inch minimum conduit shall be used for field connections.

9.5.5 Provide fluorescent lighting that meets the required electrical classification for the
interior of enclosures and houses. The light intensity 30 inches above the floor shall be
at least 40 foot-candles with a uniform distribution. Locate the fixtures to minimize
glare on the instrument panels.

9.5.6 Provide one duplex electrical outlet for maintenance in each house or shelter. Provide a
second duplex outlet at a separate location if the floor space exceeds 75 square feet.
The outlets shall meet the required electrical classification.

9.5.7 Each analyzer and its associated equipment shall have a separate circuit.

9.5.8 Each circuit breaker panel shall have a minimum of 20% spare breakers and a
minimum of 20% spare conductors for future additions.

9.5.9 All probe-type analyzers shall have unions and enough flex conduit to remove the
probe in a simple manner for calibration.

9.5.10 All electrical equipment shall be grounded in accordance with Article 250 of the
National Electrical Code. Each analyzer house shall have a ground bus of 2/0 bare-
stranded copper cable around the inside bottom of the house and connected to the plant
grounding system. The breaker panel neutral, the center tap of any transformer, and
each analyzer shall be bonded to the ground bus. The grounded end for analyzer signals
should be at the DCS for systems that have them. For older electronic systems the
ground should be at the analyzer.

9.6 Ventilation and Air-Conditioning - Totally Enclosed House

9.6.1 Provide filtered, forced-air ventilation to meet NFPA 496, latest edition requirements.

9.6.2 Provide air-conditioning to maintain temperature within the following limits:

1. Maximum house temperature = 75°F with the following conditions:
a. All equipment operating simultaneously
b. House doors closed - normal ventilation
c. Weather conditions per analyzer enclosure checkoff sheet
2. Minimum house temperature = 60°F with the following conditions:
a. All analyzers off
b. House doors closed - normal ventilation
c. Weather conditions per analyzer enclosure checkoff sheet.
9.6.3 Houses shall have thermostat-controlled electric heating coils installed at forced draft
inlet ducts and return lines. They shall be designed to automatically maintain

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temperature above 60°F at the lowest ambient temperature specified by the Company.
As an alternative, subject to Company approval, the house may be equipped with a
steam radiator suitable for the building classification.

9.6.4 As an alternative to air-conditioning and with the approval of the Company, forced-
draft fans shall be installed on the roof of the enclosures and shall be able to provide
0.1" of H2O pressure per NFPA 496, latest edition. This requires an air dispenser for
even distribution of air. The vent air shall escape via a number of outlet openings that
shall be carefully designed and located in order to avoid accumulation of flammable
gases in dead corners and to ensure the required over pressure. Air outlets shall be
provided in the walls flush with the floor and in the walls below the roof.

9.6.4.1 Rain protection and a screen covering the fan suction are required.

9.6.4.2 The fan shall be located on the roof or 6 feet above the floor on the side of the
building. In order to draw in uncontaminated air in a potentially hazardous
location an air intake 25 feet above grade can be utilized.

9.6.4.3 The fan blades shall be made of nonsparking material. The fan motor shall be
suitable for Class I, Div. 1 areas, if installed within the duct work. If installed
outside the duct work it shall be suitable for Class I, Div. 2 areas.

9.6.4.4 A 150-watt alarm light with a red globe and guard shall be provided on the
outside wall above each door of the analyzer enclosures. This light shall be
wired to indicate failure of the forced ventilation fan. Failure will be sensed
by a loss of air flow from the outlet of the fan or air conditioning.

9.6.5 (Optional) The analyzer house shall be force-draft ventilated (positive pressure) by two
air fans. Each fan shall be sized to supply a minimum volume equivalent of eight air
changes per hour within the whole enclosure. (Only one fan will be in operation at any
one time. Loss of flow on one fan will automatically start the other fan.)

10.0 REQUIREMENTS FOR FINAL APPROVAL BY COMPANY

10.1 Factory Inspection/Test

A visual inspection and test will be conducted by Company inspectors (assisted by the
Fabricator) to determine that:
1. Analyzer systems conform to this specification.
2. Mechanical and electrical systems conform to applicable codes.
3. Sample conditioning systems conform to sample system drawings. A documented
check of flow paths is required.
4. Electrical wiring conforms to circuit diagrams. A documented point to point ringout of
wiring is required.

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10.2 Each analyzer shall be individually tested by the Fabricator for the following purposes:
1. To demonstrate that there are no faults in the analyzer or sample system.
2. To document that the analyzer meets the specifications listed on the Specification
sheet, particularly for accuracy (or reproducibility), linearity, and drift.
3. To provide a standard of performance that shall be duplicated in the pre-commissioning
test after the analyzer is installed in the plant.
10.2.1 The factory test procedure shall be written by the Fabricator and transmitted to the
Company for review at least 3 weeks prior to the test demonstration date. The factory
test procedure shall include the following:
1. A list of the tests to be performed with blanks for data entries and results
extracted from recorder charts. (It is not necessary that a step-by-step
procedure be written. Refer to the manufacturer's instruction manual where
detail is needed.)
2. A description of the performance tests for accuracy and drift. (The
drift/repeatability test shall be a minimum 24-hour test with no automatic or
manual zero/span corrections. With written approval of the Company,
automatic zero corrections may be used for the gas chromatograph drift test.)
3. A description of the functional test. (This shall include the automatic and
manual calibration, alarm, and shutdown features, and signal transmission.)
4. A description of the liquid or gas mixture that will be used to simulate the
plant sample
10.2.2 The Company shall be given 2-weeks' advance notice of the factory test, including
documentation with recording charts showing that the analyzers are functioning and
ready for inspection.

10.2.3 A complete performance test including the 24-hour drift/repeatability test may be
required prior to sending personnel to the previously mentioned witnessed tests The
drift/repeatability test need not be witnessed by the Company. A shortened version may
be requested by the Company but normally, review of the test records may be adequate.

10.2.4 If the analyzer does not perform within specification requirements, corrective repairs
shall be made and the tests repeated. Every effort shall be made to avoid delays during
the formal factory test.

10.2.5 The Company will sign an approval of the factory test before the analyzer system is
shipped to the plant site.

11.0 SHIPPING REQUIREMENTS

11.1 The analyzer system shall be completely assembled before shipment. Loose equipment that
requires assembly at the plant site is not permitted (with the exception of cylinder regulators,
which shall be shipped loose).

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11.2 The size of the system shall conform to laws regulating the dimensions of structures transported
on public highways.

11.3 Provide lifting-eyes on the analyzer system to permit lifting with a crane at the construction site
without damage. Provide lifting-eyes for a four-point lift with a single hook. The lifting-eyes
shall be located on the pad of heavy structures and cable spreaders shall be provided to avoid
damage to the structure.

11.4 The analyzer systems shall be shipped in air-cushioned vans to avoid vibrational stress.

11.5 Provide adequate support and bracing of heave-mounted equipment to protect from damage
due to vibration during shipment. Cross-braces shall be provided on the openings of three-sided
shelters to prevent deflection during shipment.

11.6 All shipments should be made FOB the job site.

12.0 DOCUMENTATION REQUIRED

12.1 As-Built Drawings

The following documents shall be finalized in accordance with each as-built analyzer system.
Reproducible copies shall be provided at factory inspection time.
1. Analyzer Specification sheet for each analyzer
2. Sample conditioning system schematic drawing and layout drawing with a list of major
equipment
3. Outline drawing of the system showing the equipment layout and dimensions
4. Electrical wiring schematic showing signal and power wiring
12.2 Systems Manuals

12.2.1 The systems manuals shall include the following for each analyzer in the system:
1. As-built documents listed in Section 10.1 of this document.
2. Complete specifications on all analyzers and other equipment used in the
analyzer system.
3. Operating instructions including principle of operation for all analyzers and
their sample systems.
4. Maintenance instructions for all analyzers and their sample systems, including
preventive maintenance.
5. Test reports which document factory test results for all analyzers.
6. Recommended spare parts lists for all analyzers, sample systems, and major
equipment.
7. List of recommended calibration standards and carrier gases.
8. List of recommended supplies.
12.2.2 The systems manuals shall be complete and contain such detail that they will convey to
field personnel, proper operation and maintenance information without the need for

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outside reference. This shall apply to all analyzers and all equipment that is ancillary
to the analyzers, such as calibration equipment, transmitters, converters, modems,
control panels, processors, recorders, indicators, valves, and pumps.

12.2.3 The systems manuals shall be provided along with the system when it is delivered.

13.0 FIELD WORK REQUIREMENTS

13.1 Field Inspection

13.1.1 The Fabricator shall inspect the analyzer systems after they have been installed in the
field by others.

13.1.2 The Fabricator shall submit a report to the Company describing any problems with the
installed analyzer systems and recommended corrections.

13.1.3 The Fabricator shall assist in performing corrective work as requested.

13.2 Field Testing

13.2.1 The Fabricator shall assist in performing the "Precommissioning Test" that is a repeat
of the factory test and shall include the performance tests and the 24-hour repeatability
test. See the analyzer enclosure checkoff sheet to see if this is required.

13.2.2 The installed analyzers shall be made to perform with the same quality as demonstrated
in the factory test.

13.3 Training

The Fabricator shall provide on-the-job training for Company maintenance personnel during the
precommissioning test. Additional classroom training sessions shall be conducted at Company
request.

14.0 REFERENCES

American Petroleum Institute

API Recommended Practice RP-555, Process Analyzers

Instrument Society of America (ICM)

ISA Recommended Practice RP-12.1, Electrical Instruments in Hazardous Areas

ISA Recommended Practice RP-12.4, Instrument Purging for Reduction of Hazardous Area
Classification

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National Fire Protection Association (NFPA)

NFPA No.496 Purged and Pressurized Enclosures for Electrical Equipment in Hazardous Locations

National Electrical Code

Standard Specification

ELC-EG-1675 Installation of Electrical Facilities

15.0 ATTACHMENTS (Provided By Specifying Engineer)

1. Analyzer summary list
2. Analyzer Specification Sheets, ICM-DS-4809
3. Acceptable analyzer and sample system components list
4. Conceptual analyzer system schematics
5. Acceptable Vendors list
6. Analyzer Enclosure Data Sheet, ICM-DS-4362.
Comment 15.0 The purpose of this section is to list the attachments that make this document
specific for the job at hand. For example, list the Analyzer Specification Sheets and the total number
of pages. This is an appropriate place to put the user-modified acceptable Vendors list. Note that
these should be modified based on a particular location's experience with the analyzers and
components. Refer to Section 800, "Analyzer Instruments," of the Instrumentation and Control
Manual for the Bill of Materials for components and for possible Vendors. Keep in mind that spare
parts, Vendor accessibility, local training and other factors will change the list. Conceptual analyzer
package schematics can help provide a quick visible definition of the project.

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