Integrated Analyzer Systems and Shelters.pdf

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TECHNICAL SPECIFICATION

INTEGRATED ANALYZER SYSTEMSAND SHELTERS I4440E BASE

DATE: 03 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 1 OF 7

NOTE: BEFORE USING ON A PROJECT, THIS BASE SPEC MUST BE REVISED AS A PROJECT SPEC WITH APPLICABLEPROJECT DETAILS.

TABLE OF CONTENTS

Section Title Page No.

1. GENERAL ......................................................................................................................................1

1.1 Scope..............................................................................................................................................11.2 KBR Documents, Codes, and Industry Standards .........................................................................11.3 Drawings and Data .........................................................................................................................21.4 Inspection and Shop Test ...............................................................................................................31.5 Service Engineer ............................................................................................................................51.6 Shipping and Marking.....................................................................................................................51.7 Identification/Nameplates ...............................................................................................................52. RESPONSIBILITY ..........................................................................................................................62.1 Analyzer System Supplier...............................................................................................................62.2 Purchaser........................................................................................................................................7

3. DESIGN AND MATERIALS ...........................................................................................................73.1 Job Site Conditions And Utilities.....................................................................................................7

1. GENERAL

1.1 Scope

1.1.1 Process analyzer systems and shelter shall be supplied in strict accordance with:

Attached Data SheetsThis SpecificationKBR Purchasing Standard I2-1PS

(Note: KBR will be referred to as the Purchaser)

1.1.2 Where special features or improvements over the standard specification are required, these shall bespecified on the Instrument Data Sheets and shall be adhered to by the Supplier.

1.1.3 The Supplier shall retain full responsibility for designing, fabricating, or procuring the item or items toperform in accordance with the specified operating and service conditions specified in the Instrument DataSheets. The Supplier's responsibility for complete compliance shall not be relieved, in whole or in part, byanything contained in or omitted from this specification.

1.1.4 The Supplier shall furnish with his proposal a bill of material describing in full detail each of the deviceswhich shall be supplied with the completed system. Failure on the part of the bidder to furnish sufficientinformation to evaluate the system quoted will be considered sufficient reason to reject said bid.

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 theRequisition. Current editions of the industry standards including all mandatory addenda in effect at the time ofthe Order shall apply unless otherwise indicated.

KBR DOCUMENTS4-7TS, "General Welding Requirements"I2-1PS, "Purchasing Requirements for Instruments and Components"I44201E, "Gas Chromatographs"







AMERICAN PETROLEUM INSTITUTE (API) API RP 551, "Process Measurement Instrumentation" API RP 552, "Transmission Systems" API TP 555, "Process Analyzers"

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) ASME B1.20.1, "Pipe Threads, General Purpose (Inch)" ASME B31.3, "Process Piping"

CODE OF FEDERAL REGULATIONS (CFR) 29 CFR 1910.119, "Process Safety Management of Highly Hazardous Chemicals"

INSTITUTE OF ELECTRICAL AND ELECTRONIC ENGINEERS (IEEE)

IEEE C37-90.1, "Surge Withstand Capabilities (SWC) Tests for Protective Relays and Relay Systems"

INSTRUMENTATION, SYSTEMS, AND AUTOMATION SOCIETY (ISA) ISA 50.1, "Compatibility of Analog Signals for Electronic Industrial Process Instruments"

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) NFPA 70, "National Electrical Code"NFPA 496, "Purged and Pressurized Enclosures for Electrical Equipment"NFPA 497, "Classification of Flammable Liquids, Gases, or Vapors and of Hazardous (Classified) Locations

for Electrical Installations in Chemical Process Areas"

1.3 Drawings and Data

1.3.1 In addition to the information furnished in the quotation, as a supplier, the Supplier shall expeditiouslysubmit any drawings or test data required by Purchaser for planning, layout, installation, maintenance, andrecord purposes. The number of copies and the format shall be specified in the Purchase Order.

1.3.2 The Supplier shall identify all drawings and data with Purchaser job number, complete Purchase Ordernumber, Client's name, job location, item number and service description. The Supplier's drawings and datasheets shall include revision boxes to describe the latest revisions in full detail.

1.3.3 The Supplier shall furnish certified "as built" drawings in the form specified on the Purchase Order. Thedrawings shall show as a minimum:

a. All dimensions.b. The size, type, location, and identification of all electrical field connections. (Terminal boxes)c. The size, type, location, and identification of all utility connections.

d. Wiring diagrams for the complete system identifying all termination. These drawings shall include wiringtype, size, and shielding, also these diagrams shall clearly identify each connection to be made byPurchaser.

e. The drawings and documents shall be in English.f. US Customary Units shall be used.







1.3.4 The following engineering drawings and documents shall be submitted for approval:

a. Drawing Index, Shelter b. Substructure (Skid) Detail

c. Door and Wall-Panel Location d. Front and Left Elevation

e. Rear and Right Elevation f. Plan View, Shelter

g. Floor Plan, Shelter Interior h. Electrical Arrangement Diagram

i. Tubing and Piping Arrangement Diagram j. Power Wiring Schematic

k. Interconnection Wiring Diagram l. Interconnection Utilities Diagram

m. Sample Systems n. Structural Calculations

o. Lifting Details/Setting Details p. Cylinder Racks

q. Loop Diagrams r. Electrical Loads Summary

s. HVAC Loading t. Utility Usage.

1.3.5 Bill of materials, complete with manufacturer's name, model number, and quantity. Model numbers shallbe complete so as to allow purchasing of exactly the same replacement part.

1.3.6 Detailed (dimensional) drawings of process and utility bulkheads shall be submitted for written approvalby the Purchaser before their construction.

1.3.7 Documentation and all software which is required to install and start-up the analyzer shall be shipped withthe system.

1.3.8 For analyzers containing radioactive or ionizing sources, all details of the source shall be forwarded to thePurchaser within 4 weeks of order placement to allow site safety and local operating permits to be obtained.

1.4 Inspection and Shop Test

1.4.1 The Supplier shall be responsible for complete and detailed inspection of all materials, instruments andcomponents of the analyzer systems. The Client and/or Purchaser shall inspect and/or accept all analyzersbefore they are shipped to the Supplier for installation in the house.

1.4.2 The Client and/or Purchaser may inspect equipment and system assemblies during the course offabrication at their discretion with a minimum of 24 hours notice. A Supplier representative shall accompany theClient and/or Purchaser at the Supplier facilities. The latest drawings and bills of material of the items shall beavailable to the Purchaser's inspector at the time of inspection.

1.4.3 The Supplier shall submit detailed test procedures and complete functional check-out for acceptance six

weeks prior to the Factory Acceptance Test (FAT). The Supplier shall give the Purchaser and/or Client twoweeks advance notice of the date and time of the final inspection and test to be witnessed by the Purchaserand/or Client. The system shall not be submitted for final test until the Supplier acknowledges, in writing, thatthe system is fully operational.

1.4.4 Factory Acceptance Test (FAT): Upon completion of fabrication and assembly, all systems shall bethoroughly tested (including point wiring continuity check and piping/tubing leak test), calibrated, and undergocomplete twenty-four (24) hour functional and analytical tests as a system. This will include performance runswith Purchaser/Client supplied samples where practical, with acceptance by Client and/or Purchaser. Thesetests shall be completed prior to shipment to the job site.

1.4.5 Inspection and test shall be as follows:

a. All items furnished by the Seller shall be checked against the final approved drawings.







b. All analyzer components, tubing, sample systems and utility piping shall be helium leak tested with a bubble

tester. Each system including analyzer and any system components supplied by the Supplier shall bepressurized to 50 psig (345 kPag) with Helium. Maximum leakage through the bubbler shall be one bubbleor less in 60 seconds. If pressurized at other than 50 psig (345 kPag) with Helium, the maximumpermissible leakage rates are as follows:

1. Gas systems - 5 percent change per hour of the specified design pressure.

2. Liquid Systems - No visible leakage.

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

d. The complete analyzer system(s) shall be tested and set up to verify the correct functioning of the suppliedequipment 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 beused for system checkout. A continuous operational test shall be conducted for each analyzer for aminimum of 24 hours. This 24 hours operational test may be waived by Purchaser and/or Client if such testhas already been performed at the analyzer factory. All recordings shall be submitted together with a copyof the test report to the Purchaser for approval. Costs for the above operation tests shall be listedseparately in the Supplier's quoted price. Data collected during the 24 hour operational test shall be

subjected to statistical analysis; all readings of measured components shall be within ± 3σ (standarddeviation) of specified purity.

e. All alarms or alarm functions, safety systems, and other devices required by the Order shall bedemonstrated for proper function.

f. If the factory test is not run at the specified voltage and frequency, the suitability of the equipment for thespecified voltage and frequency shall be established by nameplate data of equipment components orcertified by the equipment components' manufacturers.

g. Hydrostatic testing on pipe shall be done as follows:

1. All piping shall be hydrostatically tested at 1 1/2 times the design pressure.

2. Piping systems in vacuum service shall be tested for full vacuum.

3. Austenitic stainless steel piping shall be tested and flushed with water having less than 500 ppm (500mg/L) chlorides. Potable water will meet this requirement. The piping and tubing shall be drainedimmediately after flushing and dried by blowing with clean filtered air.

h. On gas chromatographs, where background components in the sample may interfere with the measured

components, the concentration of these components shall be varied to demonstrate that measurement isfree of any interference.

1.4.6 All inspections and testing shall be documented in writing by the Supplier and submitted to the Purchaserfor approval. Shipment cannot be made without written approval from the Purchaser. All costs associated withinspection and customer witness testing shall be included in the Supplier's quoted price for the analyzersystems.

1.4.7 Site Acceptance Test (SAT)

Client and/or Purchaser shall witness testing after the system is installed at the jobsite. The Supplier shall havecompleted all checking and operational testing prior to notifying Purchaser that system is ready to test.







1.5 Service Engineer

The Process Analyzer Supplier shall provide a Start-Up Service Proposal to include a competent ApplicationsEngineer for review of the installation, to supervise calibration and provide initial plant-site start-up. Proposalshall state terms of this service. The person should be competent, familiar with project requirements, andexperienced in trouble shooting, diagnosing the problems, and bringing the analyzer system on line. In anycase, the process analyzer's physical and performance warranties shall be preserved for Client.

1.6 Shipping and Marking

1.6.1 The Seller shall furnish a master shipping list, in advance of the shipment, listing total quantities of eachsection, subassembly, or piece required for the complete shipment.

1.6.2 The Seller shall include a packing list in each shipment, listing the contents by assembly piece mark,

individual instrument tag number and piece mark, or by item number of each box, crate, bag, and skid. The listshall state whether the contents are complete or partial.

1.6.3 The Seller shall include, on all shipments, a copy of each instruction manual, all drawings required forassembly, installation, or erection; and one extra copy of all data required under Paragraph 1.3.1. Thesedocuments preferably shall be attached to the inside of the largest crate in the shipment and this crate shall bemarked accordingly. (Copies are independent of SDR, Supplier Data Requirements.)

1.6.4 All openings shall be plugged or blanket to keep our foreign matter. Threaded connections shall be fittedwith a plug for the female end, and a thread protector for the male end.

1.6.5 The analyzer shelter and all equipment that is supplied by Supplier shall be packaged properly foroverseas shipment. The Supplier shall supply the Purchaser with shipment details.

1.7 Identification/Nameplates

1.7.1 The Process Analyzer Shelter Supplier shall permanently affix nameplates to both sides of each wallpenetration, clearly identifying source and/or service of that line. The shelter itself shall have a permanentlyaffixed nameplate indicating Project Number, P. O. Number, Date of Order, and analyzers that are mountedinside. Nameplates shall be white laminated plastic with letters engraved into the black core (Gravoply orequivalent). Tags shall be fixed in place with RTV sealant on interior locations and with stainless steel screwson exterior locations.

1.7.2 Analyzers and related equipment shall have the following identifying information on their nameplatepermanently fastened to the analyzer.

a. Equipment identification number.

b. Manufacturer's name, model, serial number, operating range, output signal and range, and supply voltageand frequency.

c. Pressure rating of supplied components.

d. Materials of parts exposed to process fluids.

e. Electrical area clarification for which analyzer is suitable.







2. RESPONSIBILITY

2.1 Analyzer System Supplier

2.1.1 The Supplier shall be responsible for the design, construction, purchasing (as required) and testing ofeach analyzer system and analyzer shelter. All materials and system design shall meet or exceed specificationsdescribed in this document. Material selection and system design are subject of Client and/or Purchaser'sacceptance. The Supplier shall comply with any local rules or regulations which are specified by the Purchaser.

2.1.2 The Supplier shall be responsible for all wiring and piping from the analyzer system to well-defined junctions outside the analyzer shelter. The analyzer system shall include all required sample conditioning andhandling equipment and peripherals described in this requisition and the reference documents.

2.1.3 The Supplier shall provide sizing of sample line to calculate the transport time to meet the sample

analysis time requirements.

2.1.4 The Supplier shall be responsible for informing the Purchaser of all services, equipment and utilitiesrequired at the analyzer shelter. The Supplier shall provide drawings and documents the Purchaser will requirefor connecting utilities and sample lines to the analyzer house.

2.1.5 The Supplier shall be responsible for the commissioning and testing of the analyzer system and shallmake available technical assistance during the guarantee period.

2.1.6 The Supplier shall be responsible for providing on site training, as required, by the Client for the operation,maintenance and repair of all the equipment in the analyzer system.

2.1.7 The Supplier shall be responsible for providing all test equipment, carrier gases and related equipment forthe FAT test. Supplier shall specify any required gases at the time of initial offering or proposal.

2.1.8 The Supplier shall submit a monthly progress report on all phases of engineering including the analyzerdelivery, drawing review, material purchases, construction, factory testing, on-site installation, on-site testingand start-up. The Supplier shall inform the Purchaser immediately of any delivery slippages greater than twoweeks that is related to any component within the Supplier's scope of work.

2.1.9 The Supplier shall provide details of tie-down attachments, dimensions and construction notes offoundation pads.

2.1.10 Any design acceptance by the Client and/or Purchaser does not relieve the Supplier of the responsibilityto provide systems which perform the required analysis.

2.1.11 The Supplier shall provide any special tools and hardware for assembly.

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 takenshall be noted on a paragraph by paragraph basis.

2.1.14 The Supplier shall provide in his quotation a complete list of utilities required, such as cooling water,instrument air, steam and electrical power. The list shall include quantities, flow rates, pressures, voltage andother defining parameters for the utilities to be supplied by the owner, including minimum quality and maximumpressure rating for all required utilities. In addition, the Supplier shall identify all consumables, such ascalibration and carrier gases, and provide anticipated rates of consumption for the analyzer systems proposed.







2.1.5 The Sample System shall be designed with personnel safety in mind. Suitable precautions shall be taken

for toxicity, burns from exposure to hot spots and venting to safe locations. Supplier shall provide pressure reliefvalve to prevent overpressure. Venting to flare header is not permitted, unless approved by the Purchaser.Supplier shall meet government regulations such as EPA and OSHA.

2.2 Purchaser

2.2.1 The Purchaser shall provide analyzer data sheets with appropriate stream composition data and physicalconditions. The Purchaser shall purchase the gas chromatographs and shall have them delivered to theSupplier for installation and testing in the analyzer shelter. The Supplier shall be responsible for the design andmanufacturing of the sample systems as needed for the gas chromatographs delivered for installation andtesting.

2.2.2 The Purchaser shall be responsible for providing the utilities to the analyzer house in the field. Theseshall include air, water, steam, electricity, etc., along with any other service required in writing by the Supplier.

The Supplier shall provide, in writing, the quantities, loads, etc., of the utilities required.

2.2.3 The Purchaser shall review and comment on Supplier's specification and design of the analyzer samplesystems and the analyzer house.

3. DESIGN AND MATERIALS

3.1 Job Site Conditions And Utilities

3.1.1 Job Site Conditions

Barometric Pressure - 101.36 kPaa / 14.69 psig Ambient Temperature - 19 to 35

oC / 66 to 95

oF

3.1.2 Utilities Available

1. Cooling Water - 31oC at 760 kPag (88

oF at 110 psig)

2. Instrument Air - Clean, dry, and filtered at 551.6 kPag, 700 kPag maximum

3. Steam - 1035 kPag saturated (150 psig)345 kPag saturated (50 psig)

4. Power - 433 VAC, 50 Hz, 3 phase