January 2016 Process Control PIP PCEPA003 Process Analyzer System Field Installation Guidelines
PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES In an effort to minimize the cost of process industry facilities, this Practice has been prepared from the technical requirements in the existing standards of major industrial users, contractors, or standards organizations. By harmonizing these technical requirements into a single set of Practices, administrative, application, and engineering costs to both the purchaser and the manufacturer should be reduced. While this Practice is expected to incorporate the majority of requirements of most users, individual applications may involve requirements that will be appended to and take precedence over this Practice. Determinations concerning fitness for purpose and particular matters or application of the Practice to particular project or engineering situations should not be made solely on information contained in these materials. The use of trade names from time to time should not be viewed as an expression of preference but rather recognized as normal usage in the trade. Other brands having the same specifications are equally correct and may be substituted for those named. All Practices or guidelines are intended to be consistent with applicable laws and regulations including OSHA requirements. To the extent these Practices or guidelines should conflict with OSHA or other applicable laws or regulations, such laws or regulations must be followed. Consult an appropriate professional before applying or acting on any material contained in or suggested by the Practice. This Practice is subject to revision at any time. Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at Austin, 3925 West Braker Lane (R4500), Austin, Texas 78759. PIP Member Companies and Subscribers may copy this Practice for their internal use. Changes or modifications of any kind are not permitted within any PIP Practice without the express written authorization of PIP. Authorized Users may attach addenda or overlays to clearly indicate modifications or exceptions to specific sections of PIP Practices. Authorized Users may provide their clients, suppliers and contractors with copies of the Practice solely for Authorized Users purposes. These purposes include but are not limited to the procurement process (e.g., as attachments to requests for quotation/ purchase orders or requests for proposals/contracts) and preparation and issue of design engineering deliverables for use on a specific project by Authorized User s client. PIP s copyright notices must be clearly indicated and unequivocally incorporated in documents where an Authorized User desires to provide any third party with copies of the Practice. PUBLISHING HISTORY August 2000 Issued August 2006 Complete Revision January 2016 Complete Revision Not printed with State funds.
January 2016 Process Control PIP PCEPA003 Process Analyzer System Field Installation Guidelines Table of Contents 1. Introduction... 2 1.1 Purpose... 2 1.2 Scope... 2 2. References... 2 2.1 Process Industry Practices... 2 2.2 Industry Codes and Standards... 2 3. Definitions... 2 4. Pre-Installation... 2 4.1 General... 2 4.2 Receiving... 3 4.3 Civil/Structural... 3 5. Field Installation... 3 5.1 Analyzer Shelter... 3 5.2 Field Hardware... 3 5.3 Utility Piping... 4 5.4 Sample Tubing... 4 5.5 Electric Heat-Traced and Pre-Insulated Tubing... 5 5.6 Steam-Traced Tubing Bundles... 6 5.7 Sample Probe... 7 5.8 Electrical Equipment... 7 Process Industry Practices Page 1 of 8
1. Introduction 1.1 Purpose 1.2 Scope 2. References This Practice provides guidelines for the field installation of process analyzer systems. This Practice describes guidelines for field installation of process analyzer systems. Applicable parts of the following Practices and industry codes and standards shall be considered an integral part of this Practice. The edition in effect on the date of contract award shall be used, except as otherwise noted. Short titles are used herein where appropriate. 2.1 Process Industry Practices (PIP) PIP PCSPA002 - Process Analyzer System Data Sheet Instructions PIP PCSPA002-D - Process Analyzer System Data Sheet 2.2 Industry Codes and Standards 3. Definitions National Fire Protection Association (NFPA) NFPA 70 - National Electrical Code (NEC) owner: The party who owns the facility wherein the process analyzer system will be installed purchaser: The party who awards the contract to the supplier. The purchaser may be the owner or the owner s authorized agent. supplier: The party responsible for installing the process analyzer system. 4. Pre-Installation 4.1 General 4.1.1 Before installing the analyzer system equipment in the field, a pre-installation meeting should be held between the owner, purchaser, and supplier to review all associated analyzer system installation drawings. 4.1.2 If required to assist with start-up, calibration, and/or initial operation, analyzer original equipment manufacturer (OEM) service representatives and/or analyzer system vendor personnel should be scheduled. Analyzer OEM s assistance may also be required for warranty validation. 4.1.3 Installation of all analyzer equipment should be performed by trained, experienced workers. Process Industry Practices Page 2 of 8
4.2 Receiving 4.2.1 Personnel should be assigned to coordinate the arrival of equipment on site. Coordination instructions should include time, location, and date of scheduled delivery; safety requirements for driver of the delivery truck; unloading plan; storage plan; permits; ancillary equipment, etc. 4.2.2 Personnel should be assigned to verify that all equipment required for unloading and installation is present at the site. 4.2.3 Personnel should be assigned to make provisions for process analyzer systems that require immediate purging and/or power for climate control. 4.2.4 The provisions, associated field requirements, storage, and handling should be communicated to field construction personnel. 4.3 Civil/Structural 5. Field Installation 4.3.1 The analyzer system location should be verified to be in accordance with area space, elevation, and orientation requirements. 4.3.2 The foundation or platform preparation should be verified to be in accordance with purchaser s specifications. 4.3.3 The cylinder rack installation preparation (e.g., ramp access for wheeled cylinder carts, paving, and elevation of cylinder connections) should be verified to be in accordance with purchaser s specifications. 5.1 Analyzer Shelter 5.1.1 Field-mounted analyzer enclosure or shelter should be leveled and secured to support foundation. 5.1.2 Base support structure should be sealed to foundation with appropriate sealing compound. 5.1.3 For installation of a shelter without a floor, the shelter sealing gasket should be checked to ensure proper installation. 5.1.4 Ancillary shelter equipment such as awnings/rain shields, detached cylinder racks, fresh air intake, sample recovery systems, etc., should be installed. 5.1.5 The heating, ventilation, and air conditioning (HVAC) condensate drain line should be connected to the condensate drain header or sewer. Draining condensate freely on a concrete pad should not be permitted. 5.2 Field Hardware 5.2.1 Plate- or cabinet-mounted equipment locations should permit maintenance access. 5.2.2 All components should be in accordance with purchaser s specifications. 5.2.3 Clamps and brackets should be galvanized or stainless steel. Process Industry Practices Page 3 of 8
5.2.4 Tubing supports should be provided and installed with fittings, spacers, clamps, guides, and other accessories as required. 5.2.5 All sample-wetted materials should meet or exceed the materials of construction described in the purchaser s piping specifications. 5.3 Utility Piping 5.3.1 Utility piping should be in accordance with the purchaser s piping specification. 5.3.2 Utility piping should include local isolation valves, drain valves, and check valves, as specified. 5.3.3 Piping to drains should be routed under the slab or in such manner that the piping is not a tripping hazard and does not limit access around the analyzer shelter. 5.3.4 The utility piping specification break should be at the connecting flange to the analyzer shelter. 5.3.5 If steam is required for heating remote analyzer equipment, each user should have an individual supply with an isolation valve and trap. 5.3.6 Threaded piping connections should be sealed with PTFE sealing tape or equivalent tape-type sealer. 5.3.7 Piping should be leak-checked according to project/location procedure and analyzer specification. The piping should be repaired, flushed, and dried as required. 5.3.8 Utility piping should be cleaned and degreased before final connection to the utility headers of the analyzer system. 5.4 Sample Tubing 5.4.1 Sample tubing should be in accordance with process analyzer system data sheet (e.g., PIP PCSPA002-D), purchaser s specification, size, and material. 5.4.2 Only pre-cleaned tubing should be used for sample-wetted surfaces. Specific applications may require post-installation cleaning. 5.4.3 Field-tubing runs should be grouped to benefit from use of common support members and to present a finished installation that is routed in a neat and orderly manner. 5.4.4 Tubing spacing should be adequate and uniform. Tubes should not be permitted to cross over one another. 5.4.5 Only industry-standard tools should be used for bending to avoid flat spots and kinks. Bent tubing should be de-burred to the original internal diameter and blown free of particles. 5.4.6 Tubing supports should be installed in accordance with specification, tube material, and service. Tubing trays or perforated angle supports should be used as needed. Galvanic isolation is needed when tubing and support are dissimilar metals. Process Industry Practices Page 4 of 8
5.4.7 High-quality two-ferrule tube fittings should be used for gas cylinders and for all sample-wetted lines. 5.4.8 Continuous tubing runs should be used wherever possible to minimize the number of tubing unions. 5.4.9 If run in trays, tubing should be equally spaced on the same plane leaving a ¼-inch air gap. If tubing unions are used, the unions should be installed in a raised and staggered fashion away from the plane, using short 45 bends for ease of assembly and disassembly. If possible, tubing unions should be visible. 5.4.10 All installed tubing should be pressure-tested and leak-checked. 5.4.11 Pressure sensitive instrumentation should be isolated before pressure testing. 5.4.12 If a vapor sample can contain liquids or condensables, the sample line should be sloped. The sample line may slope in two directions (toward the sample tap and toward the analyzer), but both slopes should be continuous from the high point. Traps in the sample line should not be permitted. 5.5 Electric Heat-Traced and Pre-Insulated Tubing 5.5.1 Manufacturer s instructions should be used for proper installation of electrically heated and/or pre-insulated sample lines and bundles, including the following: a. Minimum bending radius b. Spacing between bundles c. Maximum spacing of supports d. Use of terminator kits e. Connections to electrical supply f. Penetrations through enclosures, e.g., safety precautions 5.5.2 Both ends of heat-traced sample tubing should be sealed with the manufacturer s recommended kits to prevent moisture damage. 5.5.3 The circuit for electrically heat-traced tubing should include equipment for ground fault protection in accordance with NFPA 70. 5.5.4 Heat-traced and pre-insulated tubing should be installed in accordance with the purchaser s specifications. 5.5.5 Tubing trays or perforated angle supports should be used as needed. 5.5.6 Sample lines should be properly secured. To prevent the creation of hot spots, care should be taken to ensure that the sample line securing devices do not deform the tube bundle. 5.5.7 Manufacturer s instructions should be checked before shortening electrically heated self-regulating sample line. 5.5.8 Heat-treated and pre-insulated tubing should be run directly to the device it serves. Process Industry Practices Page 5 of 8
5.5.9 Bulkhead tubing unions should not be permitted for cabinet or enclosure penetrations. 5.5.10 Bundle(s) should penetrate the walls of the enclosure using heat-shrink entry seals to ensure that the sample temperature is uniformly maintained. 5.5.11 Tubing connections for electrically traced tubing should be installed inside the enclosure. 5.5.12 The power source for traced tubing should be provided at either of the following locations: a. Analyzer enclosure b. Dedicated heat-tracing panel 5.5.13 Traced sample lines that have exposed surface temperatures exceeding plant safety standards should, for personnel protection, be shielded or routed away from normal reach. 5.5.14 Electrically traced tubing bundles should be checked for proper resistance or continuity before being powered. 5.6 Steam-Traced Tubing Bundles 5.6.1 Manufacturer s instructions should be used for proper installation of steamheated sample lines and bundles, including the following: a. Minimum bending radius b. Spacing between bundles c. Maximum spacing of supports d. Use of terminator kits e. Penetrations through enclosures f. Safety precautions 5.6.2 If steam is used for heat tracing, the sample line should be sloped. 5.6.3 Unions and splices in the steam lines should be minimized. 5.6.4 Steam traps should be located and steam lines should be insulated in accordance with manufacturer s recommendations. 5.6.5 Steam-traced tubing should be installed in accordance with the purchaser s specifications. 5.6.6 Tubing trays or perforated angle supports should be used as needed. 5.6.7 Sample lines should be properly secured. To prevent the creation of hot spots, care should be taken to ensure that the sample line securing devices do not deform the tube bundle. 5.6.8 Steam-traced tubing should be installed directly to the device it serves. 5.6.9 Bulkhead tubing unions should not be permitted for cabinet or enclosure penetrations. Process Industry Practices Page 6 of 8
5.6.10 Bundle(s) should penetrate the walls of the enclosure using heat-shrink entry seals to ensure that the sample temperature is uniformly maintained. 5.6.11 The steam source should be provided at either of the following locations: a. Analyzer enclosure b. Other appropriate source 5.6.12 Traced sample lines that have the exposed surface temperatures exceeding specified safety standards should, for personnel protection, be shielded or routed away from normal reach. 5.6.13 Each steam line should have a dedicated trap located in accordance with manufacturer s recommendation. The traps should not be insulated and should be installed at the lowest convenient point. 5.6.14 Seal kits should be installed on each end of steam-traced sample lines to prevent corrosion. 5.7 Sample Probe 5.7.1 Flanged sample probes used to extract the sample from the process line should be installed before hydraulic testing of the lines. 5.7.2 Proper isolation of the analyzer system should be verified. 5.7.3 Retractable insertion probes should be retracted before leak testing. Any support requirements for installations in the horizontal plane should be verified. 5.7.4 In-situ analyzer-sensing elements such as ph, conductivity, chlorine, viscosity, etc., should be installed only after leak testing. 5.7.5 Orientation of the sample probe or sensor installation should be verified. 5.7.6 Sample-conditioning equipment at the sample tap should be close-coupled to the tap and mounted and installed in accordance with purchaser s drawings. 5.7.7 Heating requirements for the sample probe and conditioning equipment, if any, should be verified. 5.8 Electrical Equipment 5.8.1 Electrical components should have a nationally recognized testing laboratory approval. 5.8.2 Conduit, metal-clad, or tray cable wiring can be used. 5.8.3 AC and DC wiring sizes and color codes should be in accordance with purchaser s requirements. 5.8.4 Field wiring and connections should be loop-checked for continuity and conformance to purchaser s drawings. 5.8.5 Junction box or electrical cabinet penetrations should be through the sides or bottom only. Process Industry Practices Page 7 of 8
5.8.6 If conduit wiring is used, covers on conduit fittings should be checked to ensure that they are properly secured. After all inspections are complete, conduit seals should be poured and marked. 5.8.7 Conduit drains should be used at each low point. 5.8.8 The shelter and all electrical equipment should be grounded. Process Industry Practices Page 8 of 8