Integrated Analyzer Systems and Shelters.pdf

TECHNICAL SPECIFICATION

DATE: 03 APR 2003

INTEGRATED ANALYZER SYSTEMS AND SHELTERS

I4440E BASE

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 APPLICABLE PROJECT DETAILS.

TABLE OF CONTENTS Section 1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2. 2.1 2.2 3. 3.1

Title Page No. GENERAL ......................................................................................................................................1 Scope..............................................................................................................................................1 KBR Documents, Codes, and Industry Standards ................... ............................ .................. ................... ................... ................... .................1 .......1 Drawings and Data ................... ............................ ................... ................... .................. ................... ................... .................. ................... ................... ................ ................. ...........2 .2 Inspection and Shop Test .................. ........................... ................... ................... ................... ................... ................... ................... ................... ................ ................ ...........3 .3 Service Engineer .................. ........................... ................... ................... .................. .................. .................. ................... ................... .................. ................. ................. ...............5 ......5 Shipping and Marking ................... ............................ ................... ................... .................. ................... ................... .................. ................... .................. ................. ...............5 ......5 Identification/Nameplates Identification/Nameplates .................. ............................ ................... ................... ................... ................... ................... ................... ................... ................. .................5 .........5 RESPONSIBILITY ..........................................................................................................................6 Analyzer System Supplier............... Supplier ................................ ................. ................. ................................. ................ ................. ................... ..........6 .......... 6 Purchaser........................................................................................................................................7 DESIGN AND MATERIALS ...........................................................................................................7 Job Site Conditions Conditio ns And Utilities ................................. ................ ................. ................................. ................ ................. ................. .................. 7

1. GENERAL 1.1 Scope 1.1.1 Process analyzer systems and shelter shall be supplied supplied in strict accordance with: Attached Data Sheets This Specification KBR Purchasing Standard I2-1PS I2-1PS (Note: KBR will be referred to as the Purchaser) 1.1.2 Where special features or improvements improvements over the standard specification are required, these these shall be specified on the Instrument Data Sheets and shall be adhered to by the Supplier. 1.1.3 The Supplier shall retain retain full responsibility for designing, designing, fabricating, or procuring the item item or items to perform in accordance with the specified operating and service conditions specified in the Instrument Data Sheets. The Supplier's responsibility responsibility for complete compliance shall not be relieved, in whole or in part, by anything contained in or omitted from this specification. 1.1.4 The Supplier shall furnish with with his proposal a bill of material describing describing in full detail each of the devices which shall be supplied with the completed completed system. Failure on the part of the bidder to furnish sufficient sufficient information to evaluate the system quoted will be considered sufficient reason to reject said bid. 1.2 KBR Documents, Documents, Codes, and Industry Industry Standards Standards The following documents are referenced referenced herein and form part of the Order. Additional KBR documents, documents, when applicable, will be listed listed on the Requisition. The issue of KBR documents shall be be as specified in the Requisition. Current editions of the industry standards standards including all mandatory addenda in effect at the the time of the Order shall apply un less otherwise indicated. KBR DOCUMENTS 4-7TS, "General Welding Requirements" I2-1PS, "Purchasing Requirements for Instruments and Components" I44201E, "Gas Chromatographs"


DATE: 03 APR 2003


I4440E BASE


PAGE 2 OF 7


AMERICAN PETROLEUM INSTITUTE (API) API RP 551, "Process Measurement Instrumentation" API RP 552, "Transmission Systems" Systems" API TP 555, "Process Analyzers" AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) ASME B1.20.1, "Pipe Threads, General General Purpose (Inch)" (Inch)" ASME B31.3, "Process Piping" CODE OF FEDERAL REGULATIONS (CFR) 29 CFR 1910.119, "Process Safety Management of Highly Highly Hazardous Chemicals" INSTITUTE OF ELECTRICAL AND ELECTRONIC ENGINEERS (IEEE) IEEE C37-90.1, C37-90.1, "Surge Withstand Capabilities (SWC) (SWC) Tests for Protective Protective Relays and Relay Systems" 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 Flammable Liquids, Gases, or Vapors and of Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas" 1.3 Drawings and Data Data 1.3.1 In addition to the information furnished furnished in the quotation, as a supplier, the Supplier Supplier shall expeditiously submit any drawings or test data required by Purchaser for planning, layout, installation, maintenance, and record purposes. The number of copies and the format shall be specified specified in the Purchase Order. 1.3.2 The Supplier shall identify identify all drawings and data with Purchaser job number, number, complete Purchase Order number, Client's name, job location, location, item number and service description. The Supplier's drawings and data sheets shall include revision boxes to describe the latest revisions in full detail. 1.3.3 The Supplier shall furnish certified certified "as built" drawings in the form specified specified on the Purchase Order. Order. The drawings shall show as a minimum: a. b. c. d.

e. f.

All dimensions. The size, type, location, and identification identification of all electrical field connections. (Terminal boxes) The size, type, location, and identification identification of all all utility utility connections. Wiring diagrams for the complete system system identifying identifying all termination. These drawings drawings shall include wiring type, size, and shielding, also these diagrams shall clearly identify each connection to be made by Purchaser. The drawings and documents shall be in English. US Customary Units shall be used.


DATE: 03 APR 2003


I4440E BASE


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1.3.4 The following engineering drawings 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 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/Setting Details

p.

Cylinder Racks

q.

Loop Diagrams

r.

Electrical Loads Summary

s.

HVAC Loading

t.

Utility Usage

. 1.3.5 Bill of materials, materials, complete with with manufacturer's name, model number, and quantity. Model numbers shall be complete so as to allow purchasing of exactly the same replacement part. 1.3.6 Detailed (dimensional) drawings drawings of process and utility bulkheads shall be submitted submitted for written approval by the Purchaser before their construction. 1.3.7 Documentation and all software which which is required to install and start-up start-up the analyzer shall be shipped with the system. 1.3.8 For analyzers containing radioactive radioactive or ionizing sources, all details of the source source shall be forwarded to the Purchaser within 4 weeks of order placement to allow site safety and local operating permits to be obtained. 1.4 Inspection and Shop Shop Test 1.4.1 The Supplier shall be responsible for for complete and detailed inspection of all materials, materials, instruments and components of the analyzer systems. The Client and/or Purchaser shall inspect and/or accept all analyzers before they are shipped to the Supplier for installation in the house. 1.4.2 The Client and/or Purchaser may inspect inspect equipment and system assemblies during during the course of fabrication at their discretion discretion with a minimum of 24 hours notice. A Supplier representative representative shall accompany the Client and/or Purchaser at the Supplier Supplier facilities. The latest drawings and bills of material material of the items shall be available to the Purchaser's inspector at the time of inspection. 1.4.3 The Supplier shall submit detailed detailed test procedures and complete functional functional check-out for acceptance six weeks prior to the Factory Acceptance Test Test (FAT). The Supplier shall give the Purchaser and/or and/or Client two weeks advance notice of the date and time of the final inspection and test to be witnessed by the Purchaser and/or Client. The system shall not be submitted for final final test until the Supplier acknowledges, acknowledges, in writing, that the system is fully operational. 1.4.4 Factory Acceptance Test (FAT): (FAT): Upon completion of fabrication fabrication and assembly, all systems shall be thoroughly tested (including point wiring continuity check and piping/tubing leak test), calibrated, and undergo complete twenty-four (24) hour functional functional and analytical tests as a system. This will include performance performance runs with Purchaser/Client Purchaser/Client supplied samples where practical, practical, with acceptance by Client and/or Purchaser. Purchaser. These tests shall be completed prior to shipment to the job site. 1.4.5 Inspection and test test shall be as follows: a.

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


DATE: 03 APR 2003


I4440E BASE


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b.

All analyzer components, tubing, sample systems and utility piping shall be helium leak leak tested with with a bubble tester. Each system including analyzer and any system components components supplied by the Supplier shall be pressurized to 50 psig (345 kPag) with with Helium. Maximum leakage through the bubbler shall be one bubble or less in 60 seconds. If pressurized at other than 50 psig (345 kPag) with with Helium, the maximum permissible leakage rates are as follows: 1.

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

2.

Liquid Systems - No visible leakage.

c.

All dimensions shall be checked against the final approved drawings.

d.

The complete analyzer system(s) system(s) shall be tested and set up to verify the correct functioning of the supplied equipment using certified calibration calibration samples provided by the Supplier. The test samples shall be at the conditions and of the composition specified specified by the Purchaser. A minimum of two unique gases shall be used for system checkout. A continuous operational test shall be conducted for each analyzer analyzer for a minimum of 24 hours. This 24 hours operational test may be waived by Purchaser Purchaser and/or Client if such test has already been performed at the analyzer factory. factory. All recordings shall be submitted together with with a copy of the test report to the Purchaser for approval. approval. Costs for the above operation tests shall be listed listed separately in the Supplier's quoted price. price. Data collected during the 24 hour operational test test shall be subjected to statistical analysis; all readings of measured components shall be within ± 3σ (standard deviation) of specified purity.

e.

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

f.

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

g.

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

h.

1.

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

2.

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

3.

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

On gas chromatographs, where where background components in the sample may interfere interfere with the measured components, the concentration of these components shall be varied to demonstrate that measurement is free of any interference.

1.4.6 All inspections and testing shall be documented in writing by the Supplier and submitted submitted to the Purchaser for approval. Shipment cannot be made without written approval from the Purchaser. Purchaser. All costs associated associated with inspection and customer witness testing shall be included in the Supplier's quoted price for the analyzer systems. 1.4.7 Site Acceptance Acceptance Test (SAT) Client and/or Purchaser shall witness witness testing after the system is installed installed at the jobsite. The Supplier shall have completed all checking and operational testing prior to notifying Purchaser that system is ready to test.


DATE: 03 APR 2003


I4440E BASE


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1.5 Service Engineer The Process Analyzer Supplier shall provide a Start-Up Service Proposal to include a competent Applications Engineer for review of the installation, to supervise calibration and provide initial plant-site start-up. start-up. Proposal shall state terms of this service. The person should be competent, familiar with with project requirements, and experienced in trouble shooting, diagnosing the problems, problems, and bringing the analyzer system on line. line. In any case, 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 master shipping list, in advance of the shipment, listing listing total quantities of each section, subassembly, or piece required for the complete shipment. 1.6.2 The Seller shall include a packing list list in each shipment, listing the contents contents by assembly piece mark, individual instrument tag number and piece piece mark, or by item number of each box, crate, bag, and skid. The list shall state whether the contents are complete or partial. 1.6.3 The Seller shall include, on all shipments, shipments, a copy of each instruction manual, all all drawings required for assembly, installation, or erection; erection; and one extra copy of all data required under Paragraph 1.3.1. 1.3.1. These documents preferably shall be attached to the inside of the largest crate in the shipment and this crate shall be marked accordingly. (Copies are independent of SDR, Supplier Supplier Data Requirements.) Requirements.) 1.6.4 All openings shall be plugged or blanket to to keep our foreign matter. matter. Threaded connections shall be fitted with a plug for the female end, and a thread protector for the male end. 1.6.5 The analyzer shelter and all equipment equipment that is supplied by Supplier shall be packaged properly for overseas shipment. The Supplier shall supply the Purchaser Purchaser with shipment details. 1.7 Identification/Nameplates 1.7.1 The Process Analyzer Shelter Supplier Supplier shall permanently affix affix nameplates to both sides of each wall penetration, clearly identifying identifying source and/or service of that line. The shelter itself shall have a permanently affixed nameplate indicating Project Number, P. O. Number, Date of Order, and analyzers that are mounted inside. Nameplates shall be white laminated laminated plastic with letters engraved into into the black core (Gravoply or equivalent). Tags shall be fixed in place with RTV RTV sealant on interior locations and with with stainless steel screws on exterior locations. 1.7.2 Analyzers and related equipment shall have the following following identifying information information on their nameplate permanently fastened to the analyzer. a.

Equipment identification number.

b.

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

c.

Pressure rating of supplied components.

d.

Materials of parts exposed to process fluids.

e.

Electrical area clarification for which analyzer is suitable.


DATE: 03 APR 2003


I4440E BASE


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2. RESPONSIBILITY 2.1 Analyzer System System Supplier Supplier 2.1.1 The Supplier shall be responsible for for the design, construction, purchasing (as required) required) and testing of each analyzer system and analyzer shelter. All materials and system design design shall meet or exceed specifications described in this document. Material selection and system design are subject subject of Client and/or Purchaser's acceptance. The Supplier shall comply with with any local rules or regulations which which are specified by the Purchaser. 2.1.2 The Supplier shall be responsible for for all wiring and piping from the analyzer system system to well-defined junctions outside the analyzer analyzer shelter. The analyzer system shall include all required sample conditioning conditioning and handling equipment and peripherals described in this requisition and the reference documents. 2.1.3 The Supplier shall provide sizing sizing of sample line to calculate the transport time time to meet the sample analysis time requirements. 2.1.4 The Supplier shall be responsible for for informing the Purchaser of all services, services, equipment and utilities required at the analyzer shelter. The Supplier shall provide drawings drawings and documents the Purchaser will require require for connecting utilities and sample lines to the analyzer house. 2.1.5 The Supplier shall be responsible for for the commissioning and testing of the analyzer system system and shall make available technical assistance during the guarantee period. 2.1.6 The Supplier shall be responsible for 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 for providing all test equipment, carrier carrier gases and related equipment for the FAT test. Supplier shall specify any required required gases at the time of initial offering or proposal. proposal. 2.1.8 The Supplier shall submit a monthly monthly progress report on all phases of engineering including the analyzer analyzer delivery, drawing review, material purchases, construction, factory testing, on-site installation, on-site testing and start-up. The Supplier shall inform the the Purchaser immediately of any delivery delivery slippages greater than two weeks that is related to any component within the Supplier's scope of work. 2.1.9 The Supplier shall provide details details of tie-down attachments, dimensions dimensions and construction notes of foundation pads. 2.1.10 Any design acceptance by the Client and/or Purchaser Purchaser does not relieve the Supplier of the responsibility responsibility to provide systems which perform the required analysis. 2.1.11 The Supplier shall provide any special tools and hardware for assembly. assembly. 2.1.12 The Supplier shall recommend recommend and quote any additional equipment required for the calibration, calibration, programming and operation of the analyzer systems. 2.1.13 The Supplier shall respond in his proposal to each paragraph of this this specification. Any exceptions taken shall be noted on a paragraph by paragraph basis. 2.1.14 The Supplier shall provide in his his quotation a complete list of utilities utilities required, such as cooling water, instrument air, steam and electrical electrical power. The list shall include quantities, 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. utilities. In addition, the Supplier shall identify identify all consumables, such as calibration and carrier gases, and provide anticipated rates of consumption for the analyzer systems proposed.


DATE: 03 APR 2003


I4440E BASE


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2.1.5 The Sample System System shall be designed with personnel safety in mind. Suitable precautions shall be taken for toxicity, burns from exposure to hot spots spots and venting to safe locations. Supplier shall provide pressure relief relief valve to prevent overpressure. Venting to flare header is not permitted, 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 data sheets with appropriate stream composition composition data and physical conditions. The Purchaser shall purchase the gas chromatographs chromatographs and shall have them delivered to the Supplier for installation installation and testing in the analyzer shelter. The Supplier shall be responsible responsible for the design and manufacturing of the sample systems as needed for the gas chromatographs delivered for installation and testing. 2.2.2 The Purchaser shall be responsible for providing providing the utilities utilities to the analyzer house in the field. These shall include air, water, steam, electricity, etc., along with an y 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 comment on Supplier's specification and design of the analyzer sample sample systems and the analyzer house. 3. DESIGN AND MATERIALS 3.1 Job Site Conditions And Utilities 3.1.1 Job Site Site Conditions Conditions Barometric Pressure Ambient Temperature Temperature -

101.36 kPaa / 14.69 psig o o 19 to 35 C / 66 to 95 F

3.1.2 Utilities Available o

o

1. Cooling Water -

31 C at 760 kPag (88 F 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

Integrated Analyzer Systems and Shelters.pdf

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