800 Analyzer Instruments

Abstract
Analyzers monitor a specific process, product quality, or meet environmental and
safety regulatory requirements. They also provide timely process analyses for
process computer control systems.
Analyzers are categorized as on-line analyzers (often called process analyzers),
laboratory analyzers, and ambient monitors/gas detectors.
This section is directed toward engineers who have varying levels of experience
with on-line analyzers or analyzer systems. (Laboratory analyzers and gas
detector/ambient air monitors are excluded from this section).

Contents Page

810 Introduction 800-3

820 Analyzer Project Execution 800-4
821 Analyzer Project Development
822 Analyzer Project Organization
830 Sample Conditioning System Design 800-17
831 Designing Sample Systems
832 Steps in Developing a Sample Conditioning System
833 Sample Point
834 General Sample Line Considerations
835 Construction Materials
836 Sample System Components
837 Process Analyzer Sample Systems
840 Analyzer Specification 800-70
841 Required Documents
842 Analyzer System Inspection and Acceptance Procedure
843 Analyzer Shelters
850 Analyzer Installation, Commissioning, and Startup 800-75

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851 Analyzer Installation Checkout Procedure

852 Analyzer Commissioning and Startup
860 Calibration and Validation of Analyzer Output 800-76
861 Calibration
862 Continuous Validation of Analyzer Output
870 Safety 800-80
871 General
872 Sample Line and Sample System Components
873 Leak Detection
874 Sample Disposal System
875 Electrical and Ignition Problems
880 References 800-82

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810 Introduction
Successful analyzer designs require knowledge of a wide range of disciplines.
Analyzers monitor and control processes throughout the refining and petrochemical
industry and also help the company comply with environmental regulatory require-
ments. Analyzers determine the composition or properties of the sample in or near
the process. They are expected to give accurate, timely results on a 24-hour-a-day
basis with little human intervention or maintenance. All analyzer projects require
detailed engineering, proper analyzer selection, and correct installation. The manual
user will learn to specify analyzers and the accessories that are necessary for a
successful installation. The annotated version of the analyzer specifications included
in this manual should be helpful for completing the installation. The general require-
ments for the installation, startup, and commissioning of analyzers are presented
here as well as extensive information about sample system design which is a partic-
ularly important and often neglected subject.
Detailed information on specific analyzers is not presented in this section but can be
found in handbooks and analyzer repair manuals or by consulting with analyzer
specialists with access to the Company’s Refinery Analyzer Applications Reference
Document (see Reference [15] at the end of Section 800).
The following topics are discussed in detail in this manual:
Analyzer Project Execution. This section summarizes the important factors in
developing and executing a successful analyzer project. These factors include scope
development and cost estimating, project organization, and assigning roles and
responsibilities.
Sample Conditioning System Design. Sample handling system design is difficult
and should not be left entirely to the vendor. The purpose of sample-handling
systems is to deliver a clean, representative stream sample to the analyzer. Particu-
larly difficult design problems occur in mixed-phase samples and when heat tracing
is required. Sample-handling systems should be built around individual, single-
purpose, discrete components that can be interchanged easily or replaced. A crucial
factor in sample handling is the order in which conditioning operations are carried
out. The purpose of the sample-handling system and the quality of the stream must
be kept in mind.
Proper Specification of Analyzer, Shelter, Installation, and Bid Evaluation.
Specifications in this manual are useful as guidelines for the integration of analyzers
and shelters and for the installation of analyzers. The well-documented analyzer
specification sheets help attain the proper analytical results required by operations.
Proper Installation, Start-up, and Commissioning. Properly designed analyzer
systems may become unreliable as a result of utility failure, electronic noise,
improper tracing, and lack of maintenance.
Calibration and Validation for Computer Control. All analyzers require verifica-
tion of results for operations’ purposes. This section offers the means of verifica-
tion and some considerations for proper calibration.

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Safety Requirements. This section outlines safety requirements that are specific to
analyzer installations and provides referrals to the appropriate codes.
Appendices. Appendix E includes typical analyzer drawings.
References. A list of published materials on this subject is included for instrument
engineers and analyzer specialists.

820 Analyzer Project Execution

This section is designed to aid in the execution of analyzer projects. This assistance
includes developing the cost estimate and justification, along with the project orga-
nization, roles, and responsibilities.

821 Analyzer Project Development

The objective of this section is to provide a proposal, justifying the purchase of an
analyzer system. Take the following steps prior to requesting approval to purchase
an analyzer system:
1. Review and define analysis requirements
2. Locate sample point and shelter location
3. Collect process data
4. Evaluate and select method of analysis
5. Prepare preliminary scope
6. Prepare cost estimate
7. Prepare justification for analyzer (cost vs. pay out)
8. Obtain approval to purchase analyzer system
9. Write analyzer system specification

Step 1. Review and Define Analysis Requirements

Input from Operations and Maintenance is very valuable. When reviewing and
defining analysis requirements, an analyzer specification sheet helps to prompt the
necessary responses from Operations and Maintenance. The analyzer specialist’s
knowledge of not only unit operations but also analytical and sampling require-
ments is key to answering questions about the limitation of the proposed analytical
installation.
Discourage the requesting organization from requiring measurements that are “nice
to know.” Measurements of additional components in, e.g., gas chromatographs,
could increase the complexity of the system and the cycle time of the analysis.
There are, however, several questions to be asked when defining analysis
requirements:

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• What does the operational unit expect to accomplish with a new analyzer?
• Is the analysis feasible?
• Are there any vendors who have performed this analysis acceptably in the past?
If so, who are they?
• Are there any upsets that may make the analysis difficult?
• What level of precision and accuracy is required of the analyzer?
• What composition or properties are required for control?
• What is the required response time?
• What is the required on-stream time?
• What are the requirements for calibration and readout?
• Are there any special maintenance requirements?
• Are there any environmental or safety concerns specific to this process stream?
• What is the required disposal method for the sample?
• What is the method and frequency of lab testing on the same stream?
Once these questions are answered, the scope of the project can be developed.

Step 2. Locate the Sample Point and Shelter

When selecting the analyzer site, consider the area electrical classification, shelter
accessibility, availability of utilities, distance to the control room, and response time
of the analyzer. Also consider operation and maintenance requirements for other
equipment in the area.
• Where is the sample point and return location?
• Are there long sample line runs?
• Are utilities available (steam, power, nitrogen, instrument and plant air, chem-
ical sewers)?
• Is there an existing house with room for a new analyzer?
• Is the signal cable in place?
• How long will the signal cable run be to the control room?
When locating the sample point, consider response time, varying temperature, pres-
sure available, and cleanliness of the sample. Keep the sample transport time to a
minimum. Generally, balance the required conditions of the sample against expense
and required response time.

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Step 3. Collect Process Data.

Collecting process data helps to determine whether or not the analysis is feasible
and, if it is, which method is appropriate. The maximum and minimum extremes
during operation upset, start-up, and shut-down should be used. If they are not, a
process analyzer specification sheet that itemizes the volume percent of each
component to three or four decimal places is useless. It is important to consider any
possible contaminants, solids, pressure and temperature swings. Use typical process
analyzer specification sheets such as those in the specification section of this
manual which have a line-by-line explanation of requirements.
Important and often overlooked points include the maximum and minimum temper-
atures and pressures of the sample and solids content. There are simple design
changes that can prevent problems arising from bubble point or dew point of the
sample. While various types of probes and filters can be included in the design, the
suitability of each type depends upon load requirements and sample characteristics.
Consult with CRTC’s M&CS Unit specialists and local maintenance personnel
about their experiences with each type.

Step 4. Evaluate and Select Method of Analysis

The analysis method must fit process conditions. Factors that influence the choice of
analysis method include reliability, cost, response time, ease of operation, cali-
bration, and maintenance. It is good practice to talk to maintenance personnel,
operators, lab personnel, and analyzer specialists before selecting a method. In
particular, avoid an analyzer system that is unproven for the particular application
unless Operations and Maintenance are aware of this situation and support this
work. If you do prefer an unproven system, request references and investigate the
application further, before informing Operations and your management about your
decision and giving them the reasons and possible consequences.
Refer to Figure 800-1 through 800-4 for a list of typical analyzers and applications.
Consult with CRTC’s M&CS Unit specialists for a complete list of vendors
available for each application and recommendations. Chevron currently maintains
alliance agreements with both Applied Automation, Inc. and Rosemount
Analytical, Inc.

Fig. 800-1 Commonly Used Analyzer System Integrators

ATI TASC
Applied Automation Measurementation
Pastech

Step 5. Prepare Preliminary Scope.

The following elements must be included in the preliminary scope of the project:
• Design
• Integration
• Training

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Fig. 800-2 Composition Analyzers

Analyzer Type Applications Typical Manufacturers
Gas Chromatograph (GC) Column Control Applied Automation(1)
Feed Analysis Asea Brown Boveri
BTU content
GC with Temp Program Feedstocks Applied Automation(1)
(Distillation analysis) Column Sidecuts Asea Brown Boveri
Mass Spectrometer Ammonia Plant Feed Area Asea Brown Boveri
Monitoring Perkin Elmer
Ethylene Cracking Units Fisons(1)
(1) Preferred

• Spare parts
• Startup Design
• Key project personnel
• Maintenance support
• Technical support
Make some decisions early in the process, particularly those involving design and
key project personnel. (Review Section 822 for information about roles and respon-
sibilities.) Avoiding these decisions until after the cost estimate is completed may
impact both the project cost and schedule.
Design. The designer may be a Company employee, an engineering contractor, or
an analyzer systems integrator. The designer must be an analyzer engineer. The
quality of design work varies tremendously:
• Analyzer systems are generally complex and require a protective environment
and conditioned sample.
• An installation can become maintenance intensive unless the designer is experi-
enced with analyzers.
A wide variety of disciplines are involved in designing an analyzer system prop-
erly. Ideally, Operations and Maintenance provide considerable input for the design
early in the project.
Integration. It is best to select qualified “analyzer system houses” or integrators,
keeping in mind that the quality of integrators’ work varies dramatically. If you are
unfamiliar with the quality of an integrator’s recent work, visit the integrator shop
before submitting a request for quotation. Ask others at your location about their
experiences with integrators and consult with CRTC’s M&CS Unit specialists to
obtain recommendations about integrators. The current (1996) list of experienced
integrators are: Applied Automation, Pastech, ATI, Measurementation, and TASC.
Training. Training begins long before the analyzer system is complete. If the
analyzer system is new to a particular location, training is a requirement of the
project, not the maintenance department. If possible, involve maintenence personnel

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Fig. 800-3 Physical Property Analyzers

Property Applications Typical Manufacturers
Calorific Value (BTU) Process Fuel Gas Fluid Data
Natural Gas Applied Automation, Asea Brown Boveri(1)
Custody Transfer Daniel
Color Jet Fuel Ametek
Vacuum Col Sidecut Precision Scientific
Cloud Point Diesel Precision Scientific(1)
Lube Oil
Conductivity Waste Water Rosemount(1)
Boiler Feed Water Foxboro Analytical
Steam & Condensate TBI
Leeds and Northrup
Density (Gas) Gas Purity Sarasota (Redland), Solartron (Schlumberger) UGC
Fuel Gas Blending
Density (Liquid) Feedstocks Automation Products
Column Sidecuts Sarasota (Redland) Solartron (Schlumberger)(1)
Products
Flash Point Jet Fuel Precision Scientific
Diesel Fuel
Freeze Point Jet Fuel Precision Scientific
Octane (Comparators) Gasoline Blending Core Labs
NIR
Octane (In-line) Reformer Product NIR (Consult with CRTC for vendor)
Opacity Stacks Rosemount(1)
pH Acid Strength Rosemount(1)
Waste Water TBI
Corrosion Control Great Lakes Instruments
Foxboro
Pour Point Lube Oils Precision Scientific(1)
Turbidity (Suspended Solids) Waste Water Monitek
Hach(1)
Vapor Pressure Gasoline Blending Precision Scientific
Asea Brown Boveri(1)
Viscosity Feedstocks Precision Scientific(1)
Crude Col Sidecuts Brookfield
Lube Oils
Viscosity..less critical Fuel Oil Automation Products
(1) Preferred

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Fig. 800-4 Analyzers for Single or Grouped Components

Components / Range Applications Typical Manufacturers Method
Ammonia ppm Waste Water Orion, Ionics Selective-Ion
Flow Injection
Aromatics Waste Water Ametek Ultra-Violet
Sulfur Compounds Stack Gases Rosemount 9100
Bovar (Western Research 900 Series) (1)
Hydrogen Sulfide ppm Gas Streams Bovar (Western Research)
Houston Atlas, MDA Scientific
Ametek
H2S/SO2 Ratio Sulfur Plant Tail Gas Ametek; Bovar (Western Research)(1)
Methane, Ethane Stack Gases Rosemount Infra-Red
CO,CO2,H2S Combustion Control Asea Brown Boveri
Gas Purity MSA
Nitrogen Oxides ppm Stack Gases Rosemount(1)
TECO
Oxygen percent Combustion Control Rosemount In-Stack
Ametek (Thermox) On-Stack
Yokogawa Extractive
Oxygen ppm Product Gas Teledyne Electro-Chemical
Blanket Gas Delta F, Anacon
Oxygen (Dissolved) Waste Water Rosemount
Orbisphere
Phosphates ppm Boiler Feedwater Hach Titration
Steam Condensate
Silica ppm Boiler Feedwater Hach
Sodium ppm Boiler Feedwater Orion Selective-Ion
Sulfur Dioxide ppm Stack Gases Bovar (Western Research)
Rosemount(1)
Total OrganiCarbon Waste Water Astro Resources, Ionics,
Rosemount
Total Sulfur ppm Fuel Gas Houston Atlas, Applied Automation(1)
Moisture in Gas ppm Reformer Recycle Ametek
Gas Instrument Air Panametrics
Natural Gas
Water in Liquids ppm Feedstocks Panametrics
Water in Ambient Air Humidity Panametrics
(Hygrometers)
(1) Preferred

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in the physical and operational shop inspection. Schedule training to begin when the
factory personnel are on site for start up.
Spare Parts. Provide a higher level of reliability by ensuring that there is an
adequate stock of spare parts. If necessary, prepare a list of specific, suggested spare
parts. Occasionally, manufacturers offer spare parts at a slight discount when
purchased with the new equipment. If the analyzer system is a new type for the
location, the project should fund the purchase of the items on the manufacturers
recommended spare parts list (usually a one-year supply).
Startup. For a new installation, startup assistance may be necessary from the manu-
facturer or systems integrator; and this assistance can also include training mainte-
nance personnel. Make arrangements for assistance and training while developing
the project scope. Note: Startup assistance is mandatory if the analyzer technology
is new to the location.

Step 6. Prepare Cost Estimate

Listed below are the major factors contributing to the cost of an analyzer project.
This information should be available after completing steps 1-5 above.
• Analyzer and sample system design, engineering and integration
• Analyzer house or shelter design, engineering and integration
• Training and startup costs
• Installation Costs
– Power
– Signal
– Sample lines and probes
– Steam
– Cooling water supply and return
– Sewer connections
– Concrete pad
– Control room and/or analyzer room work
– Craft manpower
• Readout devices/Host computer interface
• Spare parts
• Engineering and inspection costs
• Calibration manifold
• Maintenance and technical support estimated costs
Estimates of cost vary with location, plant size, labor market, and the analyzer
requirements. Several volatile factors that influence project cost estimation include:
• Base materials from recent cost quotations.
• Labor, based on days worked, rate of pay, and efficiency.

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• Design, typically 10-15% of total project cost and higher, if contracted.

(Includes drafting and contract engineering.)
• Freight, based on mode of transportation and distance. Dedicated transporta-
tion should be used with analyzer shelters.
• Escalation of costs, typically 0.1% per month for labor and material during the
course of project.
• Overhead, typically 50-60% of labor costs.
• Undeveloped project scope, 10% for miscellaneous materials and labor costs
that were not firm on initial project estimate.

Step 7. Prepare Justification For Analyzer (Cost vs. Payout)

If the analyzer is not installed for safety or environmental purposes, it must be justi-
fied on the basis of economy. Calculate payout based on the amount of fuel saved,
the increase in product yield, higher operating efficiency, decrease in off-specifica-
tion product or the price of noncomformance. Include preventive maintenance and
technical support costs as part of the cost vs. payout calculation. Process engineers
should be able to define the cost savings provided by the analyzer measurement.

Step 8. Obtain Approval to Purchase Analyzer System

This step depends on local practice. It is important to include alternatives and to
explain why they were not chosen. This approach reassures management that alter-
natives were considered. For additional support, it may be useful to discuss your
applications with someone from another location or with someone from CRTC’s
M&CS Unit.

Step 9. Write Analyzer System Specification.

This manual contains standard specification sheets and an analyzer system specifi-
cation. The analyzer system specification is also available electronically (MS
Word). If you need more detailed information, contact CRTC’s M&CS Unit
analyzer specialists.
Another valid method of developing analyzer specifications is to employ the Equip-
ment Supplier Alliance (ESA) Process. This process is outlined in the Applied
Automation Chevron Alliance document and in the Rosemount Analytical –
Chevron Alliance Document. In summary, an analyzer system integrator is selected
through other means (not bidding) and the specification is developed in cooperation
with them. This improves the quality of the specification and can eliminate the
adversarial positions fostered by the bid/award process.

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822 Analyzer Project Organization

Introduction
This section contains information for the engineer who is responsible for the appli-
cation, selection, purchase, installation, successful start-up, and ongoing success of
an analyzer system. It is also useful to contractors, integrators, and any others who
need to know how to organize and execute an analyzer project successfully.
Included in this section are:
• Specifications and documents necessary for communicating among the owner,
builder, and contractor during the engineering phase and construction phases.
• Requirements for coordination with other groups, planning hints, and a check-
list for project roles and responsibilities.
• Milestones for ensuring the successful completion of the project.

Roles and Responsibilities

Analyzer projects involve several different engineering disciplines of the Company,
the prime engineering and construction contractor, and the analyzer systems inte-
grator personnel. Close cooperation and interaction of these personnel is necessary
for a successful project.
During the detailed engineering phase follow the suggested format in EF-885,
Analyzer Project Roles and Responsibilities. This form serves as a guide to assign
the major responsibilities of each organization and individual. Lead, approval, and
review roles are defined for each activity where appropriate. The size of the project
may affect the applicability of certain items but in general they have been devel-
oped to cover situations found on all analyzer projects. The engineer (COMPANY)
or CONTRACTOR, if designated as a lead engineer, should take a lead role in
assigning roles and responsibilities. The roles should be defined at a meeting incor-
porating representatives from Operations, Maintenance, Engineering, Process
Control, and Laboratory (where appropriate) so that all affected parties agree to the
roles.
The roles are defined as follows:
Lead - this person or organization is responsible to see that the task is completed on
time and that all affected parties buy into the decision.
Approval - Final approval authority required before implementation.
Review - The person or organization must make timely comments on the items
presented.
The individuals who take each role can come from the COMPANY, CONTRAC-
TORS, and INTEGRATOR. Of course it is expected that different individuals will
take different roles in various aspects of the project. It is also expected that the
analyzer maintenance personnel will have input and review roles. Any questions

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concerning the implementation of these roles can be referred to CRTC’s M&CS

Unit analyzer specialist.
Early in the project, work with the contractor to assign roles and responsibilities to
avoid project delays and to fulfill all obligations of the project. Be certain to give
someone the task of revising existing equipment. Send a copy of the project roles
and responsibilities to the analyzer systems integrator along with the request for
quotations.

Maintenance and Technical Support (Design)

Technical support and maintenance personnel with direct, on-line, analyzer experi-
ence and training provide expert knowledge that is key to the successful purchase
and installation of analyzer systems. Experienced analyzer engineers often ask that
analyzer maintenance personnel be present during early design and review stages of
an analyzer project.
Involving maintenance personnel early in the project offers several advantages:
• Having the analyzer maintenance technicians make contributions during the
planning steps leverages their field knowledge and gives them a pride of
ownership in a new installation.
• Being closest to the actual daily work process, analyzer maintenance techni-
cians are very sensitive to such design considerations as low-maintenance
systems, proper maintenance clearances, and safety.
• Obtaining advice of skilled analyzer technicians helps to reduce the number of
field modifications required.
• The analyzer team which includes maintenance will estimate when Operations
should assume responsibility for the analyzer system.
If experienced analyzer technicians and analyzer engineers are not available locally
to work on the project, CRTC’s M&CS Unit Analyzer group can provide such
support for every phase of design, training, and technical/maintenance support
program development.

Analyzer Systems Integrator

To ensure a successful installation, Chevron personnel, the contractor, and the
analyzer systems integrator must interact closely. The contractor transmits all offi-
cial communication between the Company and the integrator.
Figures 800-1 and 800-2 are lists of acceptable analyzer systems integrators,
analyzers, and component manufacturers for the project.
The contractor provides a scope of work to each of the analyzer systems integrators
on Chevron’s list and asks them to respond with a technical proposal and bid. The
contractor also monitors the performance of the analyzer systems integrator, the
complete installation, and the commissioning of the analyzer system.
The analyzer systems integrator provides easily maintained and correct analyzer
installations and ensures that analyzer systems are installed with all required

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ancillary equipment. Such equipment includes the means for properly conditioning
and transporting sample, protecting the analyzer from the environment, and
providing an accurate and reliable output for monitoring and control. The analyzer
systems integrator is also responsible for producing the complete engineering design
of the final analyzer system and a review of the tasks undertaken by the contractor.

Pre-Bid Meeting
The contractor schedules a pre-bid meeting to be held with the integrators approxi-
mately two weeks after sending the request for quotation. (Depending on the scope
of the project, Chevron may waive this meeting.)
During the meeting, the contractor reviews the technical proposal and defines roles
and responsibilities, answering questions or resolving technical issues to ensure that
the integrators understand the scope of the work. The integrators leave the meeting
with sufficient detail to determine the quality of the engineering design, sample
system components, analyzers, and ancillary hardware.
If necessary, the contractor may revise and re-transmit the bid request or issue an
addendum to it to obtain uniform bidding from all integrators.

Bid Review
The contractor reviews the quotations and prepares a bid evaluation and recommen-
dation for review by Chevron personnel.

Alternate Bid Approval

The project may elect to work with an alliance partner to supply the analyzers,
analyze system integration and engineering at a pre-negotiated price. This approach
eliminates the time and cost of the bid process.

Project Schedules
The contractor coordinates the analyzer work to fit within the schedule for the
overall project and advises Chevron personnel and the integrator early enough to
determine any cost impact to the Company. In the request for quotation to integra-
tors, the contractor issues a proposed project schedule, with milestones for the
installation work. (See following sample.)

Proposed Project Schedule

1. Analyzer system proposal issued for bid (__/__/__)
2. Pre-bid meeting (__/__/__)
3. Bid quotations due date (__/__/__)
4. Contractor and Company review (__/__/__)
5. Contractor awards analyzer system (__/__/__)
6. Analyzer team kickoff meeting (__/__/__)
7. Order long-delivery analyzers, equipment (__/__/__)
8. Sample system review meeting (__/__/__)

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9. Receipt of preliminary drawings (__/__/__)

10. Checkout at analyzer manufacturer (__/__/__)
11. Receipt of certified installation drawings (__/__/__)
12. Physical inspection at integrator (__/__/__)
13. Operational inspection at integrator (__/__/__)
14. Ship to field (__/__/__)
15. Documentation of as-builts (__/__/__)
16. Installation (__/__/__)
17. Field checkout (__/__/__)
18. Pre-commissioning (__/__/__)
19. Technician training (__/__/__)
20. Turnover of system to Operations (__/__/__)

Bid Proposal Required Format

The following is an outline of the required format for a bid proposal submitted by
the integrator:
• Submit a technical proposal and bid to the contractor.
• When proposing a custom item, include a standard commercial item for
comparison bid.
– Indicate the proposed benefits, including cost and performance of the
custom item.
– Include design specifications for the custom item to enable comparison
between custom and standard items.
Include the following in the bid proposal:
• One-page project summary.
• List of equipment identified by manufacturer, model, etc.
• Pricing summary, itemizing the price of each analyzer, each sample system,
shelter, etc.
• Separate statements of cost of
– Any special equipment required but not supplied.
– Engineering and design for analyzer system.
– Three sets of loop folders for each analyzer system and analyzer shelter,
with incremental cost for each additional set.
– Required calibration cylinders and racks.
– Shipment of all material.
• Project execution summary.
• Project schedule per attached Company specification.

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• Technical comments, exceptions, and clarifications (analyzers, sample systems,

calibration, and ancillary equipment).
• Technical comments on analyzer shelters, buildings (construction, features,
lifting methods, etc.)
• Comments on custom instruments (compare to commercial instruments to indi-
cate performance and cost savings).
• Special items required for the analyzer system but not included in bid.
• Optional and alternative equipment or services.
• Documentation to include all “as-built” or “as-installed” drawings not only as
electronic files for computerized drafting system compatible with plant soft-
ware but also as hard copy.
• Integrator participation in checkout of designated analyzers at manufacturer’s
site prior to shipment.
• Acceptance test at integrator’s site.
• Schedule of delivery from acceptance date.
• Startup assistance.
• Proposed integrator project team listing.

Detailed Engineering Phase

After the awarding of the contract for the analyzer system to the selected integrator,
the analyzer team attends a kick-off meeting. Company, contractor, and integrator
representatives discuss the project in detail and confirm the scope of the engi-
neering work and finalize the project schedule.

Systems Integration Phase

The analyzer systems integrator has the primary responsibility for implementing this
phase of the project; however, other members of the analyzer team monitor all
aspects of integration to ensure that the analyzer system is delivered on schedule,
which allows time for analyzer pre-commissioning.

Physical and Operational Inspections

At the integrator’s site, the contractor or Company personnel, or both carry out a
physical inspection of the items listed in Section 842.
The integrator gives Chevron and the contractor a minimum of two weeks’ notice to
schedule the physical and operational inspections.
Representatives of the Company and contractor are present at the integrator’s site
for the operational inspection during which:
• All major components operate correctly and reliably.
• Analyzers demonstrate their ability to meet their design specifications.

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• All analyzers perform a repeatability run of at least eight hours and preferably
24 hours.
For analyzers having a non-linear output, the manufacturer or integrator must
provide data defining the relationship between analyzer output and the true value.
Further details about operational inspections are included in Section 842.

Installation
The installation contractor arranges for all aspects of the analyzer system installa-
tion at the Company site. This includes temporary storage of analyzer systems and
related equipment, scheduling of Company or contract labor, gathering all neces-
sary work permits, and ensuring adherence to all Company and other related
construction guidelines.

Checkout
The checkout contractor advises the integrator when the construction phase is
completed. The integrator provides, at the Companys request, technical checkout
staff to perform an inspection of the installed system and to verify not only that all
utilities are properly connected but also that all wiring conforms to the drawings.

Pre-commissioning
The integrator tests all aspects of the analyzer systems, including all utilities, safety
systems, HVAC, and analyzers. Analyzers are run on calibration standards before
running them on the process stream. The contractor audits this work and approves
the integrator work before they leave the site.

Turnover to Operations
After reviewing the turnover criteria, the contractor turns the system over to Opera-
tions at a formal meeting with the appropriate personnel represented. Refer to
ICM-DS-4362, Analyzer Enclosure Check-off Specification for details.

Post-audit
The post audit is conducted by Company personnel and may be attended by repre-
sentatives of the contractor, Operations, and the integrator, if appropriate. All
aspects of the project are reviewed and both the positive and negative aspects noted.
They record improvements for future projects and include these recommendations
with site-specific documentation and standards.

830 Sample Conditioning System Design

Few process streams are compatible with available analyzers without some sample
modification. Hardware is required for taking a sample from the process, for trans-
porting it to the analyzer, and for adjusting pressure, temperature, and flow rate.
Hardware is also required for removing particulates, separating phases, scrubbing,
and drying. In this section, the function, operation, and limitations of individual
pieces of hardware are explained; and, wherever possible, specific

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recommendations are made. An overall design guide demonstrating four types of

samples is provided below.
While you may not find it necessary to design a sample system, you should know
what constitutes a good design so that you can approve those submitted by inte-
grator. You may use the steps in Section 832 as a checklist. Neglecting any of these
requirements may result in developing an erroneous analysis or no analysis at all.
The portion of the overall installation that is left to the customer’s discretion may
determine the success or failure of the analytical instrument.
Other resources are included as Appendix E: typical sample system drawings for
combustion control systems (extractive), pH, gas chromatographs, fuel gas specific
gravity, boiler feedwater conductivity, and infrared analyzers.

831 Designing Sample Systems

The sample must be representative of the process. The sampling time delay should
meet process control requirements. Locate the sample system in a serviceable area,
preferably on the outside wall of the shelter. Plan the local design and installation
with the advice and aid of the instrument manufacturer, process engineer, and
analyzer specialist. Ask an analyzer specialist to review any designs prepared by an
integrator and keep the sample system as simple as possible.

832 Steps in Developing a Sample Conditioning System

Obtain the required analyzer sample conditions from the vendor. These conditions
dictate the degree to which the sampling system must alter the process sample.
Failure to supply a sample compatible with the analyzer may affect the accuracy of
analysis and may either render the instrument inoperable or cause permanent
damage.
Most analyzers operate on a single-phase sample that is relatively free of moisture,
corrosive substances, and particulate material (rust, scale, or catalyst fines). The
sample should be at, or near, ambient temperature and atmospheric pressure. Few
samples meet these criteria, therefore, conditioning is necessary. Also, many process
streams are well above ambient temperature, therefore, require some means of
cooling. A few analyzers are housed in heated compartments and are operated at
temperatures as high as 300°F. Sample pressure must be reduced in most sampling
systems. Concurrent with reductions in temperature and pressure are problems with
maintaining phase integrity. These problems are discussed later.
The steps for developing a sample system are as follows:
1. Ensure that there are adequate safety provisions. Safety should be the primary
consideration when developing a sample system. Check the area electrical clas-
sification and review NFPA 496, the NEC, and API standards.
2. Determine if there are any special analyzer requirements. What are the condi-
tions of the sample? Are there pressure and temperature limitations? Does it
require a liquid or vapor phase sample? Will the output be affected by

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interfering compounds? Can the analyzer be damaged by corrosion, moisture,

or particulates?
3. It is important to follow the correct order for carrying out certain operations for
the sample stream. For each sample type, a specific sequence of operations is
recommended. (See Figure 800-5). There are exceptions to any operations
sequence, and you must decide which optional steps to select.
4. Review the process piping and visit the site if possible. Choose the sample
point where the condition of the process sample fits the needs of the analyzer
and maintenance. Should plugging occur at the sample tap, the analyzer could
be damaged permanently if the operator were unable to reach a sampling point.
5. Remove the sample from the process line with a suitable sample probe. The
sample probe should extend into the process line one-third to one-half the width
of the process line and should be located on the side or top of the line.
6. Provide a means of sample transport from the probe to the analyzer. The choice
of tubing material is dictated by the nature of the sample. The motive force may
be a pressure drop across a process pump. Orifices or in-line metering pumps
are less desirable choices. A throttle control valve should not be used at all. In
some cases, aspirating probes and eductors are acceptable.
7. Condition the sample to conform to the analyzer requirements as described
above.
8. Provide sample switching arrangements for multistream analyzers and intro-
duction of calibration mixtures. Sample switching should be kept to an abso-
lute minimum or avoided if possible.
9. Investigate the availability of modular sampling systems. Some manufacturers
provide sample conditioning components as options or as an integral part of the
analyzer. Although these systems must be reviewed carefully for reliability,
they are usually less costly than systems that are developed in-house.
10. Provide for sample disposal. Regulatory agencies are applying increasingly
stringent restrictions on venting samples. Samples can often be returned to low-
pressure points in the process which saves production costs overall. Sometimes
the sample must be returned to a chemical sewer, recycle tank, or a vent or flare
header.

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Fig. 800-5 Sequence of Operations for Sample Types

Gas Sample with Condensibles Retained
1. Prefilter (hot)
2. Reduce pressure (hot)
3. Cool (above dewpoint, optional)
4. Knockout (optional)
5. Coalesce (optional)
6. Heat
7. See final sequence
Gas Sample with Condensibles Rejected
1. Prefilter (hot), optional
2. Cool (to required dewpoint)
3. Knockout
4. Coalesce
5. Heat
6. Reduce pressure
7. See final sequence
Liquid Sample to be Vaporized
1. Cool (optional)
2. Prefilter
3. Vaporize
4. Reduce pressure
5. Coalesce (optional)
6. Heat
7. See final sequence
Liquid Sample to remain a Liquid
1. Prefilter
2. Cool (optional)
3. Reduce pressure (optional)
4. Phase separate (optional)
5. Coalesce (optional)
6. Warm to analyzer temperature
7. Degas(optional)
8. See final sequence
Final Sequence
1. Dry (optional)
2. Filter (When possible, use a self-cleaning filter in the bypass loop and an inline filter in the slipstream to the
analyzer.)
3. Regulate pressure (optional)
4. Switch streams (avoid when possible)
5. Switch calibration stream (only if auto cal is required)
6. Adjust flow
7. Temperature match
8. Analyzer or disposal
9. Sample return

Note See Section 837 for a more detailed description of some typical analyzer sample systems that have
been successfully applied at Chevron.

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833 Sample Point

Avoid using an existing sample tap unless it meets the following conditions:
1. The tap is located at the top or side of the process line.
2. Mixing is complete and the process reaction is stable.
3. The best point is selected to provide the analysis needed for process control and
is located near the place where corrective control action is applied.
4. The sample point is located in a live stream away from poor mixing points.
Avoid possible water traps, gas pockets, and dead legs in piping.
5. The sample tap is located where a single phase exists (if possible).
6. In the process line, there is a point having moderate and constant pressure.
Sample circulation loops can be used to minimize lag time.
7. The sample temperature is moderate and constant. Try to obtain such a sample
by taking it downstream from a condenser or heat exchanger. Letting the
process do the sample conditioning not only reduces heater or cooler require-
ments in the sample system but also reduces costs and sample system volume.
8. The physical location of the sample point is chosen to be readily accessible for
maintenance and servicing and has the required utilities available. Sample,
return, and drainage problems are minimal. Sample line runs must be direct,
short, and located at a distance from hazardous work areas or hazardous
equipment.

Sample Probe
Typically, sample probe design and placement have been neglected. Do not re-use
existing probes. A properly designed probe can be the beginning of sample cleanup.
In its simplest form for clean streams, a probe can be an open-ended tube inserted
into a process stream.
Never insert a probe flush with the wall of the pipe. Samples collected from the
walls do not represent the stream because of the creep along the pipe wall and
because the flow rate along the wall is nearly zero.
For gaseous streams containing mists or suspended solids or for liquid streams
containing bubbles or solids, use a probe with the opening opposite the direction of
the flow to help reject non-homogeneous materials.
For ease of insertion or removal from a pressurized line, provide the probe with a
full port gate or a ball valve with packing gland. Be sure to consult with the analyzer
specialist, analyzer maintenance, and operations before selection of an insertion
probe which can be removed through a packing gland. It is recommended to use a
flanged probe which cannot be extracted while the line is operational, when ever
possible.
The simplest stack probe is a long tube with a series of openings on the opposite
side of the flow direction. To remove suspended material completely, add a filter to

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the tip of the probe. Common filter materials are sintered or woven stainless steel
and porous ceramic. In very dirty streams, minimize filter plugging by adding a
baffle to deflect suspended matter. Filtered probes will require occasional cleaning.
They can be removed from the stack for cleaning but will commonly be cleaned by
a blow-back system that introduces air or steam into the sample line automatically at
preset intervals.
Use steam eductor (ejector) probes, such as the Taylor steam eductor, for sampling
streams at pressures that are near atmospheric or slightly negative. Steam enters the
end of the probe through an aspirating nozzle that sucks the sample from the flue
into the sample transport line. The sample is cleaned in a water wash separator
ahead of the analyzer. To prevent line blocking, use dry steam, place a strainer in the
sample line, and slope the probe to grade.
Air or water educators are also acceptable and operate on the same principle.
Systems are designed with ejectors, located either upstream or downstream of the
analyzer. Some systems may require a back-pressure regulator.
Immediately following the probe, install a coarse y-strainer to prevent large parti-
cles from entering the remainder of the sample system.

834 General Sample Line Considerations

1. Keep sample lines short to minimize transport lag time.
2. Consider using a fast sample bypass loop, as shown in the typical drawings in
Appendix E.
3. Select smallest diameter line, suitable for the required flow rate and for the
available pressure drop. Capacities for tubing of varying diameters are shown
in Figure 800-6.
4. Provide sufficient pressure to maintain adequate velocities. Suggested flow
velocities are 5 to 10 feet/second for liquids and 20 to 40 feet/second for gases.
5. Install flow indicators and check valves to ensure that the sample flows in the
proper direction.
6. Control the temperature by steam tracing, electrical tracing. or steam or hot
water jacketing to prevent the formation of a second phase. Preinsulated steam
and electrically traced tube bundles are available commercially.
7. The following techniques are helpful in minimizing trapped particulates:
– Avoid an excessive numbers of fittings.
– Use tubing bends instead of ells when possible.
– Ream and deburr tube endings before making up the fittings.
A further incentive for avoiding excessive fittings is to minimize leakage. In-
leakage can occur even in relatively high-pressure lines. On vacuum systems, a
single-run tube bundle may be appropriate.

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8. Never apply pipe dope in sampling systems. Pipe dope may absorb or desorb
trace elements selectively or it may bleed into the sample, which would affect
the analysis.
9. Provide adequate support to avoid root-valve failure.

Fig. 800-6 Volume of Tubing and Pipe

Tube Size Wall Thickness Inside Diameter Volume Cu. Ft. Volume Gal. Per 100 Volume CC
Inches Inches Inches Per 100 Ft. Ft. Per Foot

1/4 0.028 0.194 0.0205 0.150 5.8

0.035 0.180 0.0177 0.132 5.0

0.049 0.152 0.0126 0.094 3.6

3/8 0.035 0.305 0.0057 0.378 14.4

0.049 0.277 0.0418 0.313 11.8

1/2 0.035 0.430 0.1008 0.754 28.5

0.049 0.402 0.0881 0.659 24.9

0.065 0.370 0.0746 0.558 21.1

5/8 0.049 0.527 0.1514 1.133 42.9

3/4 0.035 0.680 0.2521 1.886 71.4

0.065 0.620 0.2095 1.567 59.3

1 0.065 0.870 0.4126 3.087 116.8

0.095 0.810 0.3577 2.676 101.3

Pipe Size Inside Volume Cu. Ft. Volume Gal. Volume CC

Inches Schedule Diameter Inches Per 100 Ft. Per 100 Ft. Per Foot

1/2 40 0.622 0.211 1.578 60

80 0.546 0.162 1.212 46

3/4 40 0.824 0.370 2.768 105

80 0.742 0.300 2.244 85

1 40 1.049 0.600 4.489 170

80 0.957 0.499 3.733 141

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Sample Line Routing

Once the sample tap is located, examine the needs of the tubing for transporting the
sample to the analyzer. Accessibility is the most important factor from a mainte-
nance point of view. The locations of the lines are important to replace or tighten
fittings to eliminate leaks. The routing should take advantage of any existing struc-
tures or lines to which the sample lines can be strapped or of any instrument line
trays in which the sample tubing can be laid. Avoid sharp bends or kinks in the
lines. If possible, slope the lines down to the analyzer location and do not build
liquid traps into the system.
Support tubing in trays; clamp it to the structural steel on pipes or, as a last resort,
select heavier gage tubing to protect it from vibration and damage during construc-
tion. Do not clamp sample tubing to vibrating structures.
Avoid low spots in preinsulated tubing bundles by supporting them in trays. These
bundles are heavy and will sag from their own weight, therefore, do not support
bundles with only unistrut clamps.
To minimize transport time, keep the sample and return lines short, usually a
maximum of 300 feet. (For additional information, see Sample Line Sizing in this
manual.)

Method of Sample Transportation

The following factors determine the method selected to transport the sample to the
analyzer:
The simplest installation, a single line to the analyzer (shown in Figure 800-7a), is
acceptable for applications having the analyzer field mounted at the sample point to
keep the sample lines short. Sulfur plant tail-gas analyzers are installed this way to
eliminate the possibility of sulfur plugging the sample lines. The sample is returned
to the process because it is hazardous.
A single line with a bypass stream is the most efficient way of transporting samples
to an analyzer (shown in Figure 800-7b). This system minimizes sample waste and
reduces time lag in the sampling system to an acceptable value. Normally, a one-
minute lag time is considered to be the maximum allowed for sample transporta-
tion. Analyzers capable l of faster analysis and used in control loops may require a
more rapid sample circulation.
When sufficient pressure is not available. select a single-line sample system with a
steam, air, or water eductor that pulls the sample through the analyzer sample valve.
This system, shown in Figure 800-7c, must be installed with care. It is under
vacuum and any leakage in the sample system, up to and through the sampling
valve, results in air being drawn into the system. Drawing air into the system makes
the analysis worthless. As leakage is difficult to detect, use long, uninterrupted runs
of preinsulated tubing to decrease the number of fittings to be checked for leaks. A
back-pressure regulator is required when the eductor is in this location.

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Fig. 800-7 (a, b, & c) Single-line Sample Systems

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Select single-line sample systems only when response time is unimportant and the
material is non-hazardous. The obvious limitations of sending the fast loop to waste
are as follows:
• Pollution Avoidance - The handling and disposing of toxic sample is an issue
to be resolved because waste vented to the sewer or to the atmosphere is moni-
tored and may require clean up in another process unit.
• Cost - Disposing of waste that consists of large quantities of hydrocarbons or
other material can be expensive.
Figure 800-8 illustrates various methods of obtaining sample circulation loops.

Process Pumps
Process pumps are the best means of creating differential pressure for sampling
systems and is accomplished by taking the sample inlet off the pump discharge and
the sample return to the pump suction. Select this procedure whenever:
• a relatively constant differential pressure is maintained.
• the pump is not so remote from the process control point that time lag in the
process piping becomes a factor.
Make certain that the sample circulating back to the pump suction does not subject
the pump to overheating. Overheating is a concern if there is a restricted process
line downstream of the pump. This arrangement would increase the flow through
the sample loop and, in effect, open a bypass from the discharge of the pump to the
pump suction. If allowed to continue over a long period, this action could cause the
pump bearings to overheat.

Process Equipment
The amount of differential pressure that is available for a sample circulating loop
depends on the process and its auxiliary equipment. The pressure drop across a heat
exchanger and an accumulator can provide sample circulation to the analyzer.

Control Valves
These installations are normally avoided because control valves tend to provide
variable differential pressure. The control valve operation and the sample loop
interact when the control valve is operating at travel extremes. The differential pres-
sure providing sample flow in the sample loop is insufficient when the valve is fully
open; conversely, all of the process pressure differential is applied to the sample
loop when the valve is fully closed. This condition causes considerable flow around
the valve, possibly causing process upsets.
If you choose this type of installation, calculate the circulating loop line size based
on the existing differential pressure when the valve is at design flow. From this
calculation, be certain that, if the control valve is fully closed, the flow in the
sample loop will not exceed 10 percent of the control valve design flow. If the
amount of bypass flow is too great, investigate another means of transporting
sample flow to the analyzer.

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Fig. 800-8 Circulating Sample Loops

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Restriction Orifice
Installations of this type are restricted to low, differential pressures since small
restrictions in the process lines are unacceptable. Orifice runs for flow measure-
ment cannot provide analyzer-sample circulation as the analyzer flow bypasses the
flow-measuring device, thereby, causing an error in the flow measurement. Restric-
tion orifices may also be subject to clogging and waste process energy.

Sample Pumps
Sample pumps are the least desirable alternative as they require significant mainte-
nance. Select sample pumps only if there is no source of pressure differential in the
process unit. Avoid positive displacement pumps that are a potential hazard if any
portion of the sample loop is blocked downstream of the pump. Install a proper
relief valve to maintain sample system pressure at a safe level should any equip-
ment malfunction. Do not install internal relief valves in the pumps as they might
overheat if the internal relief valve should open. but instead install valves that
relieve to a remote process line. The section entitled. “Sample System Compo-
nents,” describes different types of pumps.

Eductors
In certain situations, eductors may replace pumps. Eductors have no moving parts.
They are shown in stack sampling in the drawings in Appendix E of this manual.

Other Considerations
Observe certain precautions when circulating loops handling volatile liquids are to
be sampled in a vapor state. Always choose a sample-return-point pressure of at
least 30 psig higher than the vapor pressure of the sample. This precautionary
measure prevents flashing of the sample in the circulation loop and the resultant
non-representative sampling.
By installing a liquid bypass stream, it is possible to reduce lag time for liquid to be
vaporized. Minimize the amount of wasted sample by vaporizing and pressure-
reducing the sample adjacent to the process sample connection. By using a probe,
minimize the volume of pipe, valve, and fittings upstream of the vaporizer.
Remember that there is a 300:1 volume ratio of vapor hydrocarbon to liquid hydro-
carbon which means that a dead liquid leg causes a long delay and renders the
sample non-representative of the process.
In situations where extremely long sample lines are a necessity (such as retrofitting
an analyzer into an existing house), install a bypass loop (see Figure 800-9). Avoid
installing this type of loop indiscriminately because it may be possible to overload
the filter or other sample system components in the secondary loop. A sample pump
may be required to achieve the extra flow in the longer lines.

Sample Disposal
When a sample return point does not exist in the process, it is necessary to decide
whether or not to discard the sample effluent to the sewer system or to provide the
means for pumping the sample back into the process.

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Fig. 800-9 Bypass Loop to Reduce Response Time

Consider sample disposal systems when:

• The sample is too valuable to discard.
• The sample is toxic or corrosive and too hazardous to discard in a chemical
sewer system.
• Discarding of hydrocarbon samples in a sewer system or to the atmosphere
must be minimized for environmental reasons.
• Discarding of hydrocarbons is prohibited.
• The cost of discarding the sample is very high.
Every effort should be made to return hydrocarbon samples to the process or, if that
is not practical, to the relief system. There are two forms of liquid sample disposal
systems: one requires an electric motor driven pump; and the other, an all pneu-
matic system. Both systems have surge pots that are maintained at atmospheric pres-
sure through a vented standpipe. The vent serves to eliminate back-pressure buildup
on the analyzer outlet, and the surge pot makes is possible for the pumps to operate
infrequently.

Electric Sample Disposal System

Figure 800-10 illustrates an electric sample disposal system that can be purchased or
built with a surge pot that vents to atmosphere through an explosion proof vent. Two
level switches actuate the pump: the high-level switch starts the explosion-proof,
motor-driven pump which continues operating until the low-level switch shuts it off.
The pump remains inoperative until the level rises to actuate the high-level switch.
The pump has sufficient head to return the sample to the process.

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Fig. 800-10 Example of Electric Sample Disposal Systems

Sizing Sample Lines

Design sample systems to provide the desired sample flow according to the
following requirements:
• Adequate speed of response. Fast response may require higher flows with
excess bypassing.
• The monetary value of the sample.
Keep the maximum allowable time delay for normal installations under one minute.
Normally, the sample lines are ½-inch; and, if a line of this size cannot provide the
required flow, add a sample pump.
To maintain the proper instrument response, multistream sequencing requires high,
continuous flow in each individual line from the process lines being monitored. If
such flows become excessive, they overload the sample-system components (filters
and coalescers) which may result in an improperly conditioned sample that eventu-
ally could damage the analyzer.
If the pressure differential in the sample system varies, the flow varies. If the pres-
sure at the sample point is sufficient to overcome the pressure drop in the sampling
system and provide the required sample flow, pressure control may be the only flow
control necessary. Design sample-system components with residence volumes small
enough to prevent both transport delays and capacitance averaging of sample
concentration transients. Sample-system components with large volumes require
more sample flowing through them to be flushed adequately. Even with consider-
able flushing. changes in composition are not readily transported to the analyzer due
to the mixing effect in the large volume sample system components. Use minimal
retention volume and residence time when designing sample systems. While you

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can reduce residence time by maintaining sample system volume and increasing the
flow, this can result in overloading the sample-system components. It is better to
reduce the volume of the sample system by maintaining short sample lines and to
optimize velocity by selecting tubing with small cross-sectional areas.

Lag Time
When designing new sample systems or checking existing systems to determine
proper flow conditions, use these methods and equations to obtain liquid and vapor
samples.
Sample transport lag time is the amount of time required to extract a representative
sample from a process line, to transport the sample to the analyzer, and to condition
the sample to be compatible with the analyzer. Do not confuse lag time with the
analyzer response time, the time required by the analyzer to indicate 95 percent of
the initial value when a step change is introduced to the analyzer inlet. The sample
transport lag time and the analyzer response time determine the total delay that
exists between an actual change in the process stream and the corresponding
analyzer output.
Analyzer response time is fixed by the choice of the analyzer. To optimize sample
transport lag time. keep the volume of the sample system to a minimum without
allowing excessive pressure drop. Usually sample flow through the analyzer is
small. Normally, fast-flow bypass streams are preferred to transport the sample to
the analyzer.
In liquid application, calculate the sample transport lag time easily by dividing the
internal volume of lines and components by the sample flow. Because liquid can be
considered non-compressible, the sample volume does not change significantly with
temperature or pressure; therefore, the lag time can be controlled by establishing the
proper flow. For gas streams, the compressibility of gases makes it more difficult to
calculate the total lag time.
For a fixed quantity of gas, the volume varies directly with absolute temperature and
inversely with absolute pressure. For a given sample flow, therefore, the actual
velocity of the gas through any portion of the system depends on the temperature
and pressure of the gas.
Normally, a gas analyzer is operated at atmospheric pressure for stability; therefore,
the simplest method for determining sample transport lag time is to relate the total
gas volume in the system to standard conditions (STP). As a result. for various
portions of the system, the volume at STP can be determined by means of the
following equation:

( 14.7 + P ) ( 530 )
V STP = V STAT ---------------------------------------
( 14.7 ) ( 460 + T )
(Eq. 800-1)
VSTP = Gas volume adjusted to standard conditions
VSTAT = Static volume (internal capacity)

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P = Pressure in PSIG
T = Temperature in °F.
Under standard conditions, the total volume of the system is the amount of gas
between the process line and the analyzer. The flow through the system (analyzer
and bypass streams) can then be established to provide the desired lag time for the
sample transport. Refer to Figure 800-11 as a sample problem.
Due to non-laminar flow characteristics and the shape of various sample system
components. it is necessary to add more sample system response time for complete
volume turnover. For both liquids and gases, a rule of thumb is to calculate the time
based on the system volume multiplied by three. The ultimate method is to run tests
on the installed system itself.

Liquid and Vapor Sample Pressure Drop and Velocity

The above description for gas streams does not take into account pressure drop
through the system. For relatively low flow and short line length, the pressure drop
should not be significant. At a high flow or long line length, however, the pressure
drop may become an important factor in the system design. In addition, although the
specific gravity of a gas or liquid does not affect the lag time calculation, it must be
considered when specifying flow control and indicating devices.
Determine the pressure drop using Figures 800-12 and 800-13.

Vaporized Liquids
An objectionable transport lag is introduced if a sample to be vaporized remains
liquid until the point where it enters the analyzer without a bypass circulating loop.
For light hydrocarbons, the ratio of vapor volume to liquid volume is greater than
200:1. If a vapor flow of 2000 cc/min is maintained downstream of a vaporizer, a
liquid flow of less than 10 cc/min flows upstream from the vaporizer. Every 10 cc of
liquid holdup in the sample line creates one minute of transportation lag. Separation
of as little as one foot can cause transportation lags of over five minutes.
Vaporize the sample either very close to the sample tap or immediately downstream
of a circulation loop, as shown in the typical gas chromatograph sample system in
Appendix E.

835 Construction Materials

Select construction materials to minimize corrosion. Analyzers and sample system
components can be harmed by the following environmental factors:
1. Condensation that may occur in conduit that has not been sealed.
2. Water that can collect in instrument enclosures.
3. Rodents who can eat wire insulation.

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Fig. 800-11 Sample Lag Time Problem (Courtesy of Pastech Corporation)

Sample Lag Time Problem SOLUTION
A gas sample handling system has been designed to Step 1:
meet the requirements for a specific analyzer applica- Determine adjusted volume (STP) from bypass point in
tion. The following information has been established or sample system to the analyzer.
calculated. Volume in item 5 @ 30 psig = 5 cc x 3 Atm = 15 scc
1. Process Conditions Volume in item 6 @ 15 psig = 5 cc x 1 Atm = 5 scc

a. Temperature: Ambient Total Volume = 20 scc

b. Pressure: 210 psig (15 Atm) Step 2:

Determine lag time from bypass point in sample system
Note: Since the temperature effects are not significant, they will
be neglected for purposes of simplicity
to the analyzer.
2. Sample Probe & Field Station (reduce to outlet
pressure of 30 psig) 20 scc
Lag Time = ------------------------ = 0.1m = 6s
a. Sample Probe: 1’ of ¼" tubing, .049" wall, static 200 scc/m
volume = 3.6 cc
Allowable transport lag time from process line to the
b. Block Valve, Filter, Regulator: Static
bypass point becomes 24 s (30 s - 6 s)
volume = 6.4 cc
Step 3:
3. Transport Line
Determine adjusted volume (STP) from process line to
a. Tubing: 3001 of ¼" tubing, .035" wall, bypass point in sample system.
static volume = 1500 cc
Volume in item 2 @ 210 psig = 10 cc x 15 Atm =
4. Sample System to Bypass Stream 150 scc
a. Tubing: 5' of ¼" tubing, .035" wall, Volume in item 3 @ 30 psig = 1500 cc x 3Atm =
static volume = 25 cc 4500 scc
b. Filter: Static volume = 20 cc Volume in item 4 @ 30 psig = 50 cc x 3 Atm =
c. Valves, etc.: Static volume = 5 cc 150 scc
5. Bypass Stream to Analyzer Flowmeter Total Volume = 4800 scc
a. Tubing: ½' of ¼" tubing, .035" wall, Step 4:
static volume = 2.5 cc Determine bypass flow for transport lag time of 24s
from process line to bypass point in sample system.
b. Valve, Flowmeter, etc.: Static volume = 2.5 cc
6. Transport Line from Sample System to Analyzer
4800 scc 200 scc
a. Tubing: 1' of ¼" tubing, .035" wall, Bypass Flow = ---------------------- = ------------------- = 12,000 scc/m
24s s
static volume = 5 cc or approx. 24 SCFH
PROBLEM Please note that for a Sample Transport Lag Time of 60
Given an analyzer sample flow of 200 scc/m, (standard seconds, the Bypass Flow would be approx. 11 SCFH.
cubic centimeters/minute) determine the required The above is a means for estimating the Sample Trans-
bypass flow (at STP) to give a maximum Sample Trans- port Lag Time. It is important to note the items which
port Lag Time of 30 seconds from the process line to have a serious impact on the lag time as opposed to
the analyzer inlet. those having a negligible effect. Should more precise
determinations be required (this would be very
unusual), it would be necessary to use complex equa-
tions, obtain accurate component volume data and line
measurements, confirm exact process information and,
as a final step, perform dynamic testing on the system
as installed.

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Fig. 800-12 Pressure Drop per 100 Feet of Tubing (Gases)

Darcy Pressure Drop per 100 Feet (psi)
Flow 1/4 3/8 1/2
(ft/m) Tubing Tubing Tubing
1 0.009 --- --
2 0.035 --- --
3 0.081
< 1.00 < 1.00
4 0.144
5 0.225 --- --
10 0.898 --- --

0.13 × f × p × v 2
Darcy Pressure Drop per 100 Ft. = ----------------------------------------
d
f = Friction Factor = 0.014
p = Density (C1-C4 Hydrocarbons) = 0.08
v = Velocity
d = I.D. Tubing
1/4 O.D. × .035 Wall Tubing has an I.D. = 0.18 in.
3/8 O.D. × .035 Wall Tubing has an I.D. = 0.305 in.
1/2 O.D. × .035 Wall Tubing has an I.D. = 0.43 in.

Q × 0.1079
Velocity (ft/sec) = -------------------------
d2
Q = Flow (ft/m)
d = I.D. Tubing (inches)
Flow 1/4 3/8 1/2
(ft/m) Tubing Tubing Tubing
1 3.33 1.16 0.58
2 6.66 2.32 1.17
3 9.99 3.48 1.75
4 13.32 4.64 2.33
5 16.65 5.80 2.92
10 33.3 11.6 5.83

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Fig. 800-13 Darcy Pressure Drop per 100 Feet (psi)

Flow 1/4 3/8 1/2
(ft/m) Tubing Tubing Tubing
1 4.6 0.33 0.06
2 8.5 1.3 0.24
3 41.7 3.0 0.54

4 - 5.3 0.95
5 - 8.3 1.5
10 - 33.1 5.95

0.13 × f × p × v 2
Darcy Pressure Drop per 100 Ft. = ----------------------------------------
d
f = Friction Factor = 0.014
p = Density Liquid HC = 41.3 (as n-Hexane)
v = Velocity
d = I.D. Tubing
1/4 O.D. × .035 Wall Tubing has an I.D. = 0.18 in.
3/8 O.D. × .035 Wall Tubing has an I.D. = 0.305 in.
1/2 O.D. × .035 Wall Tubing has an I.D. = 0.43 in.

Q × 0.1079
Velocity (ft/sec) = -------------------------
d2
Q = Flow (ft/m)
d = I.D. Tubing (inches)

Flow 1/4 3/8 1/2

(ft/m) Tubing Tubing Tubing
1 3.33 1.16 0.58
2 6.66 2.32 1.17
3 9.99 3.48 1.75
4 13.32 4.64 2.33
5 16.65 5.80 2.92
10 33.3 11.6 5.83

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4. Mud-daubers who can build nests in sample system components prior to use.
5. Components that may be subjected to elevated temperatures where air purges
have not been provided.
6. Corrosive material that may leak into the analyzer or the sample system.
Take the following precautions to help minimize corrosion problems:
1. Protect sample tubing from mechanical abuse by routing it properly or running
the tubing in tray.
2. Specify hypodermic-grade stainless or other alloy tubing and clean it thor-
oughly to remove oil film or purchase it cleaned. When selecting tubing, keep
in mind that thin-walled material is affected significantly by external corrosion.
3. Check all sample systems thoroughly for leaks.
4. Inspect all socket or seal-weld connections on sample systems. These connec-
tions can leave small internal cracks or pockets in the pipe wall where contami-
nants may accumulate.
5. Evaluate all sample system components for material that may absorb portions
of the sample or react with the sample. Do not use cork or felt filter elements in
service where the sample contains low moisture or solvents. Substitute ceramic
filters.

Material Selection
Follow the specifications in this manual and the enclosed list of noncorrosive parts.
Take care when selecting nonmetallic materials for sampling systems because the
sample composition might include components that attack nonmetallic materials.
Two methods of attack of nonmetallic materials are (1) direct solubility (i.e., solu-
bility of plastic in the sample material, as in acetone on plexiglass), and (2) solu-
bility of the plasticizers or fillers used in plastics (i.e., failure of Kel-F in
hydrocarbon solvent). Dissolving the plasticizer results in initial swelling then final
disintegration of the base material.
Reduce not only costs but also fire-and-health hazards by selecting material for the
sampling system properly.

836 Sample System Components

Piston Pumps
Piston or plunger pumps are often selected for metering applications. At the suction
stroke, the check valve on the inlet port opens and allows the chamber to fill with
fluid. At the discharge stroke, the inlet check valve closes and the moving pistons
force the fluid through the outlet port. Piston pumps are capable of a wide range of
flows by varying the stroke length and/or drive speed. Some units are capable of
generating pressures up to 30,000 psi.

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Some disadvantages of piston pumps are as follows:

• Piston pumps produce pulsating flow.
• Packings are subject to leakage and require periodic maintenance.
• Piston lubricant may contaminate the sample.
• Check valves are troublesome especially in dirty streams.

Diaphragm Pumps
Diaphragm pumps need either a mechanical or a hydraulic coupling to transmit the
plunger movement into diaphragm displacement. To vary flow, adjust the stroke
length and stroke frequency. An advantage of the diaphragm pump is that there is no
leakage past the piston and no contamination of the sample from pump lubricant.
The discharge pressure is limited because of the stress on the elastomeric
diaphragm. In mechanical linkage, the upper limit is about 300 psi whereas some
hydraulic-type pumps can withstand up to 5,000 psi.

Bellows Pumps
Bellows pumps move fluid by alternately extending and compressing flexible cham-
bers and may be fabricated from stainless steel or from a variety of polymeric mate-
rials. To adjust the pump capacity over a wide range, alter the length of the stroke
and stroke frequency.
The advantages of bellows pumps are that they can isolate the process fluid from the
pumping mechanism and can eliminate sliding seals. Discharge pressures are
limited to 50 psi.

Gear Pumps
Do not choose gear pumps for samples containing abrasives because the abrasive
cause progressively increasing internal leakage or slippage. Seal leakage is the most
common problem with this type of pump.

Centrifugal Pumps
Centrifugal pumps move large volumes of sample at relatively low pressure and
operate at comparatively high speeds. Choose centrifugal pumps with a magnetic
linkage to avoid seal and contamination problems. Centrifugal pumps are not suit-
able for high-viscosity samples and are not self-priming.

Peristaltic Pumps
In peristaltic pumps, fluid is forced along by waves of contraction produced
mechanically on flexible tubing. The primary advantage of peristaltic pumps are
their low cost, low sample holdup, and freedom from leakage and contamination.

Eductors
Eductors have the advantage of no moving parts, low maintenance, and low cost.
The motive fluid under pressure, discharges at high velocity through a nozzle and

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entrains the suction fluid. The motive fluid may be air, the process stream, steam, or
another convenient fluid.
Eductors may be installed in sampling systems at the end of the sampling train,
downstream from the analyzer, so that the sample is sucked through the analyzer
without being contaminated by the motive fluid. Alternatively, the motive fluid may
be mixed with sample and separated in the sample conditioning train. Appendix E
shows a sample system with eductors for extracting oxygen and carbon monoxide
from stack gas.

Flow Indicators
Rotameters, the most widely used flow indicators, are variable orifices consisting of
a tapered tube and float which are available armored or in glass. Usually the rota-
meter manufacturer supplies sizing information for water and air. Calculate the
approximate conversions to other fluids with the equations available in vendor
literature.
Sometimes, a sight-flow bubbler can provide continuous regulation of gas flow if
you set the adjustment to very small flow rates and time the bubbles through the
liquid. Fifty psi is the maximum pressure that can be applied to a bubbler with a
pyrex bowl and 100 psi with a plastic bowl.

Heat Exchangers
In some cases, the process stream temperatures may be above the temperature limit
of the analyzer, and heat must be removed from the sample. Sometimes heat loss
through the walls of the sample line provides adequate cooling, but often a sample
cooler is required. The heat exchange media can be water, air, freon, steam, or other
fluid.
Mechanical refrigerators are acceptable for low temperature applications. Vortex
coolers are useful for cooling small flows but consume large quantities of air. Gas-
sample coolers may result in the formation of a second phase that requires a sepa-
rator to remove the condensed material. A trap is necessary for removing large
amounts; coalescers, for small amounts.

Cooling and Heating

The following guidelines help determine if liquid samples require cooling:
1. When separation is required between condensibles and noncondensibles.
2. For analysis of steam samples.
3. When taking samples for initial boiling point, freeze cloud, and flash point.
4. To prevent flashing in sample valves.
Cool other samples if the sample temperature exceeds the temperature compensa-
tion range of the analyzer or if the temperature exceeds the capabilities of internal
heat exchangers. The most common cooling medium is cooling water.

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If cooling water is not available, is too expensive, or its temperature is not low
enough, take cold air from a vortex tube or a mechanical refrigerator.
Some samples, such as long and short residue streams, may require cooling to just
above 212°F as they may solidify at lower temperatures. In such cases, the cooling
medium may be hot condensate, the temperature of which is affected by controlling
the pressure of the steam in the steam condenser.
Heating may be required to prevent condensation of gaseous samples or to lower
viscosity of liquid samples. Ensure that the conditioned temperatures are main-
tained up to the analyzer.
Gas samples approach the temperature of their container rapidly. Heat tracing helps
to avoid plugging and corrosion from condensation of water in gas samples.

Separators
Removal of Entrained Liquids in Liquids. By gravity difference, coalesce and
further separate liquid entrainment (i.e. water in oil or opposite) and also separate
entrained gases. To prevent fouling of the coalescer packing, filter it first. Remove
solids by filtration.
Dispose of the separated entrainments into the return line of the circulation loop.
For single-line systems, use an automatic drain or gas vent.
Coalescers are effective for removing dispersed water from gas. Most process
streams contain small amounts of water which may have to be removed before the
sample reaches the analyzer. A coalescer contains a fine pore filter element that is
wetted by hydrocarbons and not water. Finely dispersed water agglomerates into
large droplets that fall out to the bottom of the coalescer.
The large internal volume of commercial coalescers require either large flows or
sample by-pass flows to avoid long lag times. The sample leaving the coalescer is
saturated and no further cooling should occur in the sample system.
Note Adhere to the flow rate recommendations provided by the coalescer manu-
facturer. If the flow rate is too high, the coalesced material may break up into small
particles that remain in floating condition and prevent separation by gravity
differences.
Removal of Entrained Liquids in Gases. By selecting the sample tap location
properly, you minimize the carryover of liquid or solid entrainment.
Obtain further separation in the sampling system by: (1) installing cyclone filters
when the sample velocity is adequate; (2) coalescing droplets for liquid entrainment
and following with gravity separation; (3) filtering solids.
Removal of Entrained Gases in Gas Streams. Remove polar compounds, such as
NH3 and CO in stack gases by scrubbing with a water cooler or water eductor.
The mixed phase enters the separator from the side or from the top. The abrupt
change in direction and the reduced velocity separates the higher-density, entrained

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material from the lower-density fluid. Heavy material is drained off periodically
either manually or automatically.
Centrifugal Separators. A cyclone separator consists of an inverted cone with a
tangential inlet near the top. Overflow connections are located at the top and center
of the cone; the drain connection, at the bottom. The efficiency of cyclones depends
on the velocity of the sample and the difference in density between the particles and
the fluid. The overflow is normally maintained at 50 percent of the total flow. The
underflow is returned continuously to the sample line.

Filters
Most process streams contain small amounts of solid or semisolid material in the
form of scale, rust, and catalyst fines. Remove at least part of this material to
prevent plugging lines and to avoid damaging the analyzer. Mechanical filtration is
available in a variety of materials and pore sizes.
To maximize analyzer performance and minimize sample system maintenance, do
not overfilter. While overfiltering is not harmful, particle removal has an effect on
the eventual plugging of filters and increased maintenance. It is important to know
the requirements of the particular installed analyzer. For example, samples for a pH
meter may require no more than a coarse wire-mesh screen filter. Gas chromato-
graph samples, however, must be free from abrasive material down to 0.3 microns
to protect delicate sample valves.
For this application, select bypass filters whenever possible as their self-cleaning
capability allows for much longer periods between replacing and cleaning elements
than other types of filters. Sample systems that need fast-flow circulation loops can
take advantage of the bypass configuration to provide the required, small, slip
stream to the analyzer. Be sure to provide sufficient flow rate in the bypass stream
to keep the filter clean or install two filters in parallel as an acceptable alternative
when it is too costly to shut down the system for tiller cleaning or essential mainte-
nance. Install pressure gages at either end of the manifold to indicate when filters
are plugged.
Size the filter housing properly to maintain a low sample-system volume for
decreased lag time.

Valves
Valves can be categorized according to their intended use, such as the following:
shutoff valves, throttling valves, and remotely operated valves.
Shutoff Valves. Shutoff, or on/off valves can be subdivided into gate, ball, plug,
diaphragm, and specialty valves, such as rotary or slider valves, common in gas
chromatographs.
Sometimes, small gate valves are selected for throttling; however, large sizes
vibrate excessively in the partially open state.

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The diaphragm valve provides a sample that is free of contamination from valve-
stem lubricant or packing. The sealed construction of this valve makes it useful for
highly corrosive streams.
When the valve is in the closed position, ball valves trap liquid in the ball cavity
which is undesirable as the trapped liquid may contaminate the next sample.
Throttling Valves. Most throttling or flow-adjust valves are variations of the basic
globe valve. The globe may be a disc, ball, plug, vee, or needle configuration. For
small flows, as in analyzer sample systems, select the miniature vee valve. For
precision metering, choose a tapered needle valve. Do not use valves of this type
for shutoff, however, because of the possible damage to the stem and potential for
leakage.
Remotely Operated Valves. The most common remotely operated valves in sample
systems are pneumatic valves or electrically operated solenoid valves. Solenoid
valves are generally limited to a maximum pressure drop of 200 psig. Special coils
are available for temperatures as high as 350°F. Multiport valves are useful for
multistream and calibration arrangements.
Air-operated valves are often chosen for high-temperature applications as their
performance for these applications can be significantly better than solenoid valves.

837 Process Analyzer Sample Systems

Introduction. The process analyzer sample system designs presented in this section
are intended as guides for engineers and designers who are involved in the installa-
tion of process analyzers. All but one of the designs are based on actual installa-
tions in various parts of the Company. They are not meant to be standards, as
sample systems are often enhanced in the field not only by experienced mainte-
nance and plant operation personnel but also as improved components are intro-
duced.
No sample system is trouble-free, and scheduled preventive maintenance is essen-
tial to attain a high analyzer service factor.
The basic requirement of a sample system is to extract a representative sample from
a process line under process conditions of temperature, pressure and particle load
and to present it, in a short time and in a suitable condition to an on-line analyzer.
Initially, compromise is essential to make most important decisions in the installa-
tion: the location of the sample take-off and of the analyzer shelter for short sample
lines. This is due to competition from other requirements of a process plant. There-
fore, it is necessary to plan the analyzer installations early in a project and to
involve other engineers and designers in the planning process.
Sample system design is usually left to an analyzer systems contractor. The design
examples that are given in this section will be useful for evaluation of the
contractor’s work.

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Chevron Research and Technology, M&CS Unit should be used as a resource and
support in all phases of the process analyzer project when there is not a site process
analyzer engineer.
Design Notes. Earlier 800 sections of this manual covered many aspects of sample
system design. Two basic requirements are mentioned here:
In almost all cases, a sample probe in the process line should be used for extracting
an analyzer sample since a probe provides initial inertial filtering, and takes a more
representative sample at a distance from the pipe wall.
A fast sample loop is a basic feature of most sample systems. This fast flowing line
brings the sample to the analyzer, thereby reducing sample lag time. Also, only the
sample needed by the analyzer is fully conditioned by filters, regulators or heat
exchangers, thereby saving maintenance.
Analyzer Integrity. When a process analyzer is in a control loop, or it is accumu-
lating data for regulatory purposes, it is essential to know if the analyzer output is
believable. Various checks have been devised to indicate whether or not this is true.
These checks vary to some extent from one type of analyzer to another.
The following are some examples:
• Low sample pressure in the fast loop.
• Low sample flow to the analyzer.
• Analyzer calibration off by more than a set percentage.
• Analyzer signal large step change.
• Analyzer being calibrated or repaired.
In the sample system designs that follow, the only integrity checks shown are flow
switches, but the need for other integrity checks should always be reviewed.

Stack Gas Sample System. Nitrogen Oxides and Continuous Emission

Monitoring Analyzers
The sample systems for continuous emissions monitors (CEMS - CO, Oxygen and
NOx) and for nitrogen oxide analyzers alone, are very similar. However, the regula-
tions which control the monitoring of NOx emissions alone, apply to all existing
furnaces, some of them fairly small. Consequently, the requirement that calibration
gases should be introduced at the sample probe on the stack does not apply.
A bypass filter, item 6, at the sample branch to the analyzer from the fast loop may
sometimes be omitted, depending on the size of the filter at the end of the probe in
the stack.
A membrane filter which holds back liquid water, has been added downstream of
the refrigerated sample drier, as a back-up device.
This filter can also be installed ahead of the diaphragm pump in case the sample line
temperature drops below the stack gas dew point.

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The following sample system components are shown in Figure 800-14. These
components are suitable for areas with a general purpose electrical classification.

Fig. 800-14 Stack Gas Sample System: For NOx & CEMS Analyzers

1. Sample Probe in Stack. This 1" or 1.5" stainless steel probe provides inertial
filtering by changing direction of flow of the sample gas. For air quality control an
external filter is recommended - the filter being accessible from the outside of the
stack. (Fabricated by contractor)
2. On-Stack Sample Control Box. This box is required to be near the sample probe
so that calibration gases and blowback air for the probe can flow through the
complete sample system. The solenoid valves in the box are remotely controlled
from a switching device such as a PLC in the analyzer house. The box is heated and
the temperature is controlled above the dew point of the stack gases. (Fabricated by
contractor)
3. Heated Sample Line. This electrically traced tubing bundle maintains the sample
at a temperature above the dew point to prevent condensation in the line. This
bundle should be of the type that uses constant wattage with a temperature
controller. Condensed liquid might absorb some of the desired components and/or
freeze in the line. (Dekoron, Parker Hannifin, or O’Brien)

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4. Air Blow-back Valve. This air-operated, 3-way ball valve is remotely operated
during the calibration cycle. (Whitey)
5. Fast Loop Air Eductor. Since the stack gas is below atmospheric pressure, a
pump is required to extract the sample. Eductors or “jet pumps” are frequently used
since they are practically maintenance free. A fast flowing sample (typically
5 ft/sec) is brought right down to the analyzer house to reduce sample lag time. A
diaphragm pump may also be used. (½" SS jet pump with an air requirement
50 psig is fabricated by Penberthy, Fox.)
6. Sample By-pass Filter. A filter (10 micron nominal) may be required here for the
sample branch to the analyzer, depending on the probe filter size. (PermaPure, PAI,
Fluid Data)
7. Pressure Gauge. A local pressure gauge (0-30 psig nominal) in the sample line
to the analyzer is a valuable indicator especially for maintenance purposes.
(Ashcroft)
8. Diaphragm Sample Pump with Bypass. This is necessary to provide a positive
sample pressure for the analyzer(s). Moisture drop-out ahead of the pump reduces
the life of the diaphragm. The sample line inside the box should be traced and insu-
lated right up to the pump. See component 11 below on using a membrane filter.
(ADI)
9. Relief Valve. A relief valve around the pump protects the pump against a
blockage downstream, whatever the cause - plugging of a filter, malfunction of a
regulator, or a valve closure. (Nupro)
10. Sample Cooler/Drier. This component should be designed for minimal contact
between the sample and the condensible materials to reduce the chance of gases
dissolving into the liquid. There is evidence that some NO2 is lost in the coolers.
(Refrigerated Sample Cooler/Drier for 5°C dew point are manufactured by M & C,
Universal Analyzers, Hankison.)
11. Membrane Filter. This filter with ¼" ports will prevent liquid water or oil from
passing and is recommended as a back-up device for the cooler/drier.
(A+ Company)
12. Pressure Regulator and Gauge. Sample conditions must be carefully
controlled to attain the sensitivity and stability of the analyzers in this application.
The regulator has ¼" connections and a range of 0-10 psig. (Go, Fairchild)
13. Valving for Analyzer Zero and Span Gases. Calibration checks are carried out
automatically every 24 hours using certified cylinder gases. The output signals of
the analyzers are automatically adjusted by auto zero and span units. These func-
tions are controlled by a dedicated PLC or other device in the analyzer house. The
calibration gases are connected to the system through valves in a block & bleed
arrangement with a bubbler leak indicator. Some regulations require the calibration
gases to be introduced at the sample probe, see component 2 above. (The 3-way,
multipurpose solenoid valves are manufactured by Skinner, Asco.)

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14. Sample Flow Indicator. To maintain correct calibration, the flow rates of the
sample and calibration gases must be the same, at the same analyzer outlet pres-
sure. The flowmeter should have ¼" connections and a range of 0.2 to 1.2 scfh.
(Brooks, Wallace and Tiernan)
15. Sample Flow Switch. The sample flow is one of the items monitored to check
“Analyzer Integrity” described in the introduction of this sub-section. (Fluid
Component Inc.)
16. Final Sample Filter. This is the final “polishing” filter before the analyzer. It is
packaged as a tee-type filter with a two micron element. (Nupro)
17. Nitrogen Dioxide (NO2) to Nitrous Oxide (NO) Converter. This converter is
necessary if a total NOx analysis is required, which is normal, since the Chemilumi-
nescent. The most efficient and stable converters operate at a temperature of about
800°F. Low temperature converters (about 350°F) using a molybdenum catalyst are
more likely to lose efficiency, and will convert a small amount of ammonia to NO,
in spite of the manufacturers’ claims. (High Temperature converter, built into
analyzer by analyzer manufacturer. Rosemount.)
18. Sample System Box. Experience gained in cogeneration units indicates that the
sample diaphragm pump needs more protection from condensation. The sample
system box should be controlled at a temperature of about 180°F and the sample
line inside the heated box should be traced right up to the pump. This ensures that
the pump has some protection against condensation when the box is opened.
19. Analyzer. The following analyzers are common for these applications:
• Oxygen: Paramagnetic
• Carbon Monoxide: Infra-Red, with CO2 and H2O compensation
• NOx: Chemiluminescent

Chromatograph sample system: FCC Stack Gas with Heavy Particle Loading
This sample system is similar to the next chromatograph sample system - gas
sample under pressure returned to header - with the following special features:
• There are two sample fast loops with two bypass filters to clean the sample. A
cyclone filter is in the first loop, a swirlklean filter is in the second loop.
• The stack gas is below atmospheric pressure so that an eductor is needed to
extract the sample.
• The sample flowing through the chromatograph sample valve can exhausted to
atmosphere. However, the fast loops are returned to the stack or duct.
The following sample components are shown in Figure 800-15.
1. Sample Probe. A plain probe with heated tubing take-off from the top of a tee
fitting at the end of the probe. The end connection is plugged so that it can be used
for cleaning the probe.

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Fig. 800-15 Chromatograph Sample System: FCC Stack Gas with Heavy Particle Loading

2. Sample Tubing. An electrically traced, self-limiting, ½" tubing bundle keeps the
sample above its dew point, to prevent condensation and possible freezing in the
line. (Parker Hannifin, Dekoron, O’Brien)
3. Cyclone Filter. This SS filter removes most particles larger than 10 microns
without an element. This type of filter is described in more detail in the component
notes on the Extended Natural Gas sample system described later in this section.
(Mooney Analytical, PAI)
4. Flow Indicator. The flow through the filter must be maintained at the specified
rate to ensure maximum particle removal. (Brooks)
5. Swirlkleen Bypass Filter. A second sample loop with a Swirlkleen bypass filter
provides further filtering. This filter is also described in the component notes for the
Extended Natural Gas Sample System later in this section. (Collins)
6. Flow Indicator. A second sample loop flow indicator has the same function as
component 4 above since the filter requires a continuous bypass flow to sweep the
particles along with the return sample to the stack. (Brooks, Wallace and Tiernan)
7. Sample Diaphragm Pump. This pump drives the sample through the chromato-
graph. To protect the diaphragm it is advisable to extend the electrical tracer, heating
the line right up to the pump, to prevent condensation in the line when the heated
enclosure is opened. (ADI, Universal Analyzers)

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8. Pressure Gauge. The sample pressure must be sufficient to drive the sample
through the chromatograph sample valve. At this point a pressure of about 20 psig is
adequate. The gauge should have a range of 0-30 psig on a 4½" dial. (Ashcroft)
Sample components 9 through 15 are the same as in Figure 800-16 below.

Fig. 800-16 Chromatograph Sample System: Gas Sample Under Pressure Returned to Header

16. Heated Enclosure. This enclosure is necessary to keep the components in the
sample system above the dewpoint. For a stack gas the temperature could be
approximately 130 deg F. The column in the chromatograph should be chosen to
accommodate the water vapor. (Hoffman)

Chromatograph Sample System: Gas Sample Under Pressure Returned to

Header
The following sample components are shown in Figure 800-16.
1. Sample Probe with Gate Valve. This full port valve has a packing gland for
probe extraction. A probe is always the preferred method of sampling for analyzers,
due to flow direction filtering, and more representative sample. (Integrated by
Contractor with gate valve for extraction, where piping code allows.)
2. Sample Block Valve. This valve at the process line is usually covered by the
piping code, and is not selected by the sample system designer. This valve is often a
¾" gate valve and is installed by field.
3. Filter. A Y-strainer is recommended upstream of the pressure regulator. (Yarway)

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4. Pressure Regulator. A differential pressure of about 20 to 25 psig will generally

be sufficient to provide gas sample flow through the system. A suitable sample
return point for the fast sample loop is necessary. (Moore)
5. Sample Line. A prefabricated line is preferred since the sample must be kept
safely above the dewpoint temperature of the gas. All expected ambient tempera-
tures and process conditions should be considered - including start-up and upsets.
(For light, dry gas streams this is not necessary.) (Electrically traced, self limiting
tubing bundle with ¼" SS lines are made by Dekoron, Parker Hannifin, O’Brien).
6. Filter. The fast sample loop is taken to the analyzer house to reduce sample lag
time. A Swirlkleen filter is required at the analyzer sample take-off from the fast
loop. (Collins)
7. Fast Sample Loop. This return line must be connected to a low pressure point in
the process so that adequate differential pressure is available for the sample system.
The line back to the process may need to be heated to prevent condensation which
could cause plugging.
8. Pressure Gauge. Local indication of sample pressure is valuable for routine
checking and maintenance purposes. The pressure gauge should have a range of
0–25 psig. (Ashcroft)
9. Final Filter. An in-line filter with a maximum 2 micron element is required to
safeguard the chromatograph column. (Nupro)
10. Bypass Flow Indicator. This bypass takes the excess gas not flowing through
the chromatograph sample valve. It also allows the flow to continue when the
sample is blocked and vented a few seconds before the sample valve injects the
measured volume into the carrier gas, allowing the gas to come to atmospheric pres-
sure. (Brooks, Wallace and Tiernan)
11. Sample Block and Vent Valves. These are air operated, ¼", SS ball valves
which are controlled by the chromatograph cycle program. As stated above, they
block and vent the sample flowing through the sample valve in the chromatograph,
to ensure that the measured volume in the loop is at atmospheric pressure. (Whitey)
12. Flow Indicator. The flow through the sample valve is continuous except when
it is blocked for a few seconds at the beginning of each measuring cycle. See
component 14 below. (Brooks, Wallace and Tiernan)
13. Differential Pressure Regulator. This component is necessary due to vent
header pressure variations. A differential pressure regulator can be used here since
the effect of sample pressure variations is eliminated by component 11 above.
(Moore)
14. Sample Valve. This valve is an integral part of the chromatograph. It directs a
continuous flow of gas through a fixed volume sample loop. At the beginning of an
analysis cycle, the valve operates and the carrier gas sweeps the volume of sample
into the column where it separates into components.

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15. Block and Bleed Valves. If calibration is controlled automatically, which is

normally the case, the calibration gases are introduced through a block and bleed
solenoid valve arrangement. See also the discussion on Figure 800-27 later in this
sub-section.

Chromatograph Sample System: Liquid Sample with Liquid Injection Valve

There are many cases where the sample is liquid under process conditions but it can
be analyzed as a vapor in a chromatograph column. Normally, it is better to trans-
port the sample as a liquid under pressure and inject it directly into the carrier gas,
where it vaporizes at the temperature of the chromatograph column.
The following sample components are shown in Figure 800-17.

Fig. 800-17 Chromatograph Sample System: Liquid Sample with Liquid Injection Valve

1. Sample Probe with Gate Valve. This full port valve has a packing gland for
extraction. It is used where piping code allows. (Integrated by contractor or chro-
matograph manufacturer).
2. Sample Block Valve. This ½" SS ball valve is used for isolating the sample
system from the process line. (Whitey)
3. Filter. This Y-strainer with 100 mesh screen is recommended before the pressure
regulator. (Yarway)
4. Pressure Regulator. It is always advisable to regulate the sample pressure
because of the level and variations in the process pressure. Also the differential

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pressure between take-off and return should be sufficient to drive the sample
through the sample system and return the sample to a lower pressure point in the
process - preferably across a pump. Range can be 20-25 psig differential.
(Moore, Go)
5. Bypass Filter. The fast sample loop is taken to the analyzer house to reduce
sample lag time, where the sample line to the analyzer is filtered by a Swirlkleen
bypass filter. (Collins)
6. Flowmeter. An armored flowmeter is required in the fast flow loop for safety
reasons for liquid hydrocarbons under pressure. (Brooks, Wallace and Tiernan)
7. Return Line Root Valve. The analyzer sample system must be protected from
the downstream process pressure even though the sample take-off valve is closed.
The root valve is normally a ¾" gate valve constructed to line specifications.
8. Sample Block Valve. This ¼" SS ball valve is necessary to have at the analyzer
house for maintenance purposes. (Nupro)
9. Bypass Flowmeter. Sample bypass at the analyzer takes excess flow not required
by the sample valve and keeps the sample flowing during calibration to reduce lag
time. (Brooks)
10. Check Valves. These ¼" SS valves prevent circulation of the sample around the
loop. (Nupro)
11. Final Filter. This ¼" SS filter protects the liquid injection valve and the chro-
matograph column. (Nupro)
12. Flowmeter. This flowmeter (0–20 ml/min) controls the flow through the liquid
sample valve. (Brooks)
13. Liquid Sample Valve. This valve injects a measured volume of the sample by
means of a grooved piston directly into the carrier gas where it vaporizes and flows
into the chromatograph column. (ABB, MAT Valve)
14 & 15. Back Pressure Regulator and Gauge. It is necessary to keep the liquid in
the system above the bubble point at the prevailing temperatures. The regulator
setting also depends on the pressure required to return the sample to the process
line. (Moore)
16. Standard Injection - This system is used when it is possible to calibrate with a
standard liquid mixture kept under pressure during storage and when sample is
injected by a liquid valve. The cylinder containing the standard has two sections
connected by a piston, with nitrogen under pressure on one side, the standard on the
other. A block and bleed valve arrangement can be used as shown. (The 3-way, air
operated, ¼" ball valves are made by Whitey.)

Chromatograph Sample System: Liquid Sample with Local Vaporizing

Regulator
A liquid stream to be analyzed by a chromatograph may contain heavy components
that would damage the chromatograph column or it may be necessary only to

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analyze the lighter components in the stream. In these cases, a vaporizer regulator is
located ahead of the chromatograph, and the chromatograph column is protected
from any liquid that has not been vaporized by a liquid knock out pot.
The following sample components are shown in Figure 800-18.

Fig. 800-18 Chromatograph Sample System: Liquid Sample with Vaporizing Regulator

1 & 2. Sample Probe with Gate Valve. (See appropriate notes in previous sample
systems.)
3. Sample Shut Off Valves. These ½" SS ball valves isolate the sample system for
maintenance. It is important to protect the system from back pressure from the fast
sample loop return point. (Nupro)
4. Heat Exchanger. This may be necessary to reduce the chance of the liquid vapor-
izing in the sample system ahead of the vaporizer. The sample should be trans-
ported at low temperatures, to allow the pressure to be reduced without the risk of
vaporizing. The bubble points under various pressures should be estimated. (Princo
2" Dial Thermometer/Sentry Cooler)
5 & 7. Fast Sample Loop Flow Indicator and Valve. See sample system design
notes at the beginning of this section. This 0–2 gpm armored flowmeter provides
control of the flow in the fast loop at the analyzer house. (Brooks)
6. Primary Filter. This Y-strainer has a 10 micron SS element. (Yarway)

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8. Secondary Sample Loop and Filter. This loop and filter bypasses excess liquid
not flowing through the vaporizer regulator and keeps the sample updated close to
the analyzer. (Collins)
9. Flow Indicator and Valve. This armored rotameter provides control for the
secondary sample loop. (Brooks)
10. Vaporizing Regulator. The liquid sample is vaporized in a heated block at the
entrance to the regulator. The vaporized sample pressure is regulated.
11. Vapor Sample Pressure Gauge. This 0–20 psig gauge indicates the pressure
driving the sample through the rest of the sample system. (Ashcroft)
12. Relief Valve. This relief (set at 10 psig) to the vent header protects the system
against a blockage downstream or malfunction of the regulator. (Nupro)
13. Liquid Knock-out Pot. This pot drains off heavy components in the sample that
have not been vaporized. (Integrated by Contractor)
14. Flow Indicator and Valve. This flowmeter (0–1 L/min) and valve control flow
of vapor to the sample valve. (Brooks, Wallace and Tiernan)
15. Sample Block and Vent Valves. These ¼", SS, air-operated ball valves bring
the sample to atmospheric pressure a few seconds before it is injected into the
carrier gas. The valves are operated by the chromatograph cycle program. (Whitey)
16 & 17. Block and Bleed Valves. This system is used when the calibration gas is
introduced automatically by the chromatograph, which is the normal case. (Skinner,
Asco)
18. Differential Pressure Regulator. Most analyzer samples must be vented to a
closed vent header, not to the atmosphere. A back pressure or differential pressure
regulator is needed because of the variations in pressure in the header. The pressure
in the sample valve does not affect the calibration of the chromatograph, due to the
operation of component 15 above. (Moore)
19. The Bypass Loop takes care of excess flow when the sample block operates or
when the chromatograph is in calibration.
20. Heated Enclosure. The sample system components from the vaporizer down-
stream must be in a heated enclosure, to prevent liquid dropping out in the lines.
The controlled temperature depends on the dew point of the vapor.

Chromatograph Sample System: Extended Analysis of Natural Gas

This design includes probe and bypass filter options in the sample system for a
continuous extended analysis of untreated natural gas by capillary chromatograph.
The term “extended” means that all the heavier components in the stream are
included in the analysis. Since some of these may be present in the line as liquids,
the extraction of a representative sample is more difficult.
The following sample components are shown in Figure 800-19.

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Fig. 800-19 Chromatograph Sample System: Extended Analysis of Natural Gas Analysis

Probe Options. In each probe option, a static mixer is recommended ahead of the
probe in the line to improve the chance of extracting all components.
• Option 1. Here a heated sidestream is intended to vaporize all the components
and to allow the flow to become laminar, so that an isokinetic probe will be
effective. The sample probe internal diameter must be large enough to mini-
mize any selective effect.
The isokinetic probe receives sample at the same flow rate as the gas flow rate
in the line, avoiding composition changes which might be caused by inertial
effects.
• Option 2. A simpler installation would have a regular ASTM type sample
probe or an isokinetic probe immediately following the static mixer without the
heated sidestream.
• Option 3. To compare with the above, a plain probe with square end opening
could be used in the line.
ByPass Filter Options. The following bypass filter options can be used:
• 4. Cyclone Filter. In this filter the sample stream enters at the large diameter of
a conical chamber. Particles move down the walls of the chamber, gaining
speed as the flowrate increases, and are swept out with the discharge. The clean

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sample is taken from the center at the top of the chamber. The filter is effective
for removing particles above 10 micron at 50 psi differential between the inlet
and the clean sample. No element is needed, thus it is very effective as a
primary element in sample conditioning.
• 5. In-line Filter. This filter is a straight-through system, in which a cylindrical
sintered metal element is held between O-rings. The sweepstream flows
through the inside of the cylindrical element, and the filtered sample is taken
off at a side connection. Elements are available down to a pore size of 0.5
microns. The whole of the element is theoretically in the filtration path, but the
area close to the outlet plugs more quickly and increases the pressure drop
across the filter.
• 6. Swirlkleen Filter. This filter combines both an element and a centrifugal
filter effect. The sample enters one side of the circular wall of a cylindrical
chamber and exits the other. This action sweeps the particles through as they
are forced to the walls under centrifugal action. The filtered sample is taken
from both ends of the chamber through sintered metal filter elements. Pore
sizes may be down to 0.5 microns. (Collins, Rosemount)
• 7. ByPass Filter/Coalescer. This filter contains a filter element, either woven
or sintered metal, which is screwed on to the top cap of the filter assembly,
surrounding the filtered sample connection. The sweepstream is around the
outside of the element, from top to bottom. A continuous flow is maintained
from the bottom, in bypass service, or the connection can be valved or plugged
for in-line service. The volume hold-up may be a problem in some applications.
8. Pressure Regulator. This ¼", SS, metal diaphragm regulator is located close to
the line to reduce the pressure rating of the sample system components and to
reduce the gas held up in the sample lines, both safety requirements. The pressure in
the sample system must be kept at a minimum - just sufficient to keep the sample
flowing, to avoid raising the dew point. The regulator range will depend on the
application. (GO)
9. Sample Line. The electrically traced, Teflon tubing bundle keeps the sample
above the dewpoint to prevent condensation and possible freezing in the line.
(Parker Hannifin, Dekoron, O’Brien)
10. Valves. These valves are provided for a sample bomb connection if a manual
sample is required.
11. Heated Enclosure. This enclosure keeps all sample components above the
sample dew point.

Supercritical Chromatograph Sample System

A supercritical chromatograph uses carbon dioxide above its critical point as a
carrier. Thus it is capable of analyzing very heavy hydrocarbon samples which are
soluble in the CO2. The most important feature of the sample handling system is
that it maintains the sample at a temperature high enough for it to flow freely
through the lines.

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The sample system shown in Figure 800-20 is the section next to the analyzer, and
does not include any components near the process line.

Fig. 800-20 Supercritical Chromatograph Sample System

1. Valves. Local sample shut-off and bypass valves allow the flow to be maintained
in the sample loop during analyzer shut downs for maintenance, etc. (Hoke)
2. Bypass Filter. The sample fast loop inside the sample box flows continuously to
keep the lag time to a minimum. The connection for the sample to the chromato-
graph is taken through a Swirlkleen bypass filter. See component notes for
Figure 800-16 for more details on this type of filter. (Collins)
3. Local Pressure Gauge. Range 0–100 psig, ¼" connections. (Ashcroft)
4. Armored Flowmeter. Bypass flow is maintained about 2.5 gpm on this indi-
cator. Full scale range is 0–5 gpm. (Wallace & Tiernan)
5. Bypass Flowswitch. This 316 SS flow switch activates an alarm when flow goes
below 1 gpm. (ChemTec)
6. Bypass Flow Control Valve. ½" SS needle valve (Hoke)
7. Double Block and Bleed Valves. Standard liquid is introduced through these for
calibration of the chromatograph. (The notes for Figure 800-27 describe these valve
arrangements more fully.) (Whitey)

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8. Flow Indicator. This armored flowmeter with a range 0–6 gph indicates the
sample flow through the analyzer. It is located on the sample outlet line from the
analyzer. (Wallace & Tiernan)
9. Sample Flowswitch. This flow switch has a range of 0–6 gph and activates an
alarm on low sample flow (set at 3 gph). (Fluid Component Inc.)
10. Sample Flow Control Valve. ¼" SS needle valve. (Hoke)
11. Block and Bleed Valve. This second valve arrangement returns the process
sample to line or the standard used for calibration to the liquid standard supply. (See
component 7 above).
12 & 13. Valves. These single, air-operated, 4-way ball valves are located in the
standard liquid introduction system. They switch the stream from the sample to the
standard. (Whitey)
14. Sample System Component Box. This insulated steel box is heated with a
steam coil and temperature controlled by a thermostat for 210° F. A window in the
box allows the two flowmeters to be seen from the outside. (The sample system box
with a subpanel for components is made by Hoffman. The temperature indicator,
Range 50°–400° F, 2" dial thermometer is made by Ashcroft).

Recycle Gas Moisture Analyzer Sample System

See reference cited in RAARD for design.

Tanker Vapor Recovery Sample System

This sample system uses an infrared gas analyzer which is a back-up for a control
system in which natural gas is mixed with vapors recovered from the tankers during
loading operations. The control system is designed to keep the vapor in the line well
above the explosive limit, and is based on flow ratio. The analyzer is sensitized to
methane.
The following sample components are shown in Figure 800-21. These components
are suitable for an area electrical classification of Class 1, Gp D, Division 1.
1. Sample Probe in Line with Gate Valve. This full port valve has a packing gland
for probe extraction. (Integrated by Contractor)
2. Sample Probe Block Valve. This 3/8" SS ball valve is used for sample cut-off at
the line. (Whitey)
3. Dual Head Diaphragm Pump. This sample pump is located near the line to
reduce the length of the pump suction line and to provide positive pressure in the
sample line. (Air Dimension)
Note that all sample lines outside the sample box are electrically traced, self-
limiting sample lines to ensure that there is no liquid drop-out in the system.
4. Sample Fast Loop Back Pressure Regulator. This 0–25 psig regulator is
mounted in the sample component heated enclosure with pressure gauge. (GO)

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Fig. 800-21 Tanker Vapor Recovery Sample System

5. Fast Sample Loop Flow Indicator. This flowmeter and valve has ¼" connec-
tions and a range of 0–15 scfh. (Brooks)
6 & 9. In-line Filters. These filters have a ¼" 0.5 micron element. (Nupro)
7. Block and Bleed Valves. This valve arrangement protects against leaky valves in
the zero and span gas system, and also ensures that the lines are swept with the
selected gas, avoiding cross-contamination of one gas with another. The valves are
air-operated, 3-way, 1/8", SS ball valves. (Whitey)
7A. Flowmeter. Any leaks in the test gas valves will be shown by this flow indi-
cator. The flow indicator range is 0–2 scfh. (Brooks)
8. Sample Flowmeter and Valve. This 0–2 scfh flowmeter and valve are used to
control the sample flow to the analyzer. (Brooks)
9. Sample Filter. This in-line SS filter has 1/8" connections, a 0.5 micron element,
and provides final filtering before the analyzer. (Nupro)
10. Flow Switch. This 1/8", 10 L/min, explosion-proof switch is part of the analyzer
integrity check discussed in the introduction to this sub-section. (Autoflow)

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11 & 12. Back Pressure Regulator and Gauge. The regulator is necessary to
maintain calibration when a gas is being measured in this type of analyzer, where
infra-red absorption is measured in a fixed volume cell. The subatmospheric pres-
sure regulator is set at 0 psig. The pressure gauge has a range of 30" to 30 psig.
(GO, WIKA)
13. Heated Enclosure. This Hoffman box houses the sample system components to
prevent condensation. (Hoffman)
14. Vent Valve. This 4-way ball valve is located downstream of the analyzer. It is
used to vent the line to atmosphere when calibration is being carried out during the
time the vapor recovery system is down. It is necessary because the pressure in the
main vapor line can then be 15 to 25 psig, making the calibration invalid under
operating conditions. (Whitey)

Capillary Viscometer Sample System: Highly Viscous or High Wax Point

Sample
The special requirements for a sample of this kind are:
• The sample must be kept above its wax point temperature at every part of the
sample system. Provision must be made to flush out the sample system with
cutter stock when the system is being shut down. This flushing avoids plug-
ging the lines with solid or viscous sample during maintenance and reduces
start-up time.
• The sample system components at the analyzer shelter are installed in a heated
box. Valves are provided to flush this section also.
• All electrical components must be suitable for Class 1, Gp D, Div. 2 electri-
cally classified area.
The following sample components are shown in Figure 800-22.
1. Sample Take-Off and Return Root Valves. These ¾" gate valves should be
heated and insulated. An extension of the tubing bundle electric tracer may be used
for short lengths. (By piping to conform with Code)
2. Flush and Drain Valves. These ½",SS ball valves should also be heated and
insulated. They are installed for flushing the sample lines with a cutter stock before
shutting down the system for maintenance etc. (Whitey)
3. Heated Sample Line. The electrically traced, self-limiting tubing bundle is used
to maintain the temperature of the line safely above the wax point of the sample. All
parts of the system outside the heated box must be heat traced and insulated.
(Dekoron, Parker Hannifin, O’Brien)
4. Heated Sample Box. This sample box must be brought up to temperature before
the viscometer pump is switched on. The temperature indicator and pressure gauge
should be visible from outside without opening the box.
This insulated sample system box includes an electrical heater and temperature
control unit. (Integrated by contractor.)

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Fig. 800-22 Capillary Viscometer Sample System: Highly Viscous or High Wax Point Sample

5. Filters. Two Y-strainers in parallel with 100 mesh screens are recommended so
that elements can be cleaned with minimum interruption of service. (Yarway)
6 & 7. Pressure Regulator and Gauge. The viscometer is not designed to handle
process pressure variations. However, the double pump model of Precision Scien-
tific is less sensitive than the Hallikainen type.
The pressure setting depends on the return line pressure. The pressure regulator has
SS components and ½" connections.
8. Temperature Indicator. This 2" dial thermometer should be visible outside the
sample box. (Princo)
9. Sample Filter. This Y-strainer with 20 micron SS mesh protects the gear pump(s)
in the viscometer from wear due to particles in the sample. A clean sample is the
single most important factor in viscometer maintenance. (Yarway).
10 & 11. Flow Indicator and Control. The sample response time is kept to a
minimum by maintaining a fast flow in the loop. The flow indicator has a typical
range of 0–30 GPM range and has ½" connections. (Universal Flow Monitors)
12. Sample Box Flush and Drain Valves. See component 2 above. (Whitey)

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13. Calibration Valves. A viscometer can be calibrated by collecting a sample at

the outlet while noting the viscometer reading. The sample is analyzed in the lab,
and any necessary adjustment to the viscometer signal (pneumatic or electronic) is
made after the fact. Alternatively, a calibration standard may be introduced directly
into the viscometer using these ¼" SS ball valves. Care is taken to circulate enough
samples of the standard to flush out the process sample. (Whitey)
14. Temperature Indicator. The sample must be ten degrees F cooler than the
viscometer bath for good control, since this depends on maintaining a load on the
bath heater. A cooling coil is also provided in the bath for circulation of cooling
water for the same reason. The temperature indicator has a 2" dial. (Princo)
15. Pressure Gauges. These gauges have diaphragm protection. Their range is fixed
by the sample return pressure (Ashcroft)

Freeze Point Analyzer Sample System (Precision Scientific)

The jet fuel freeze point analyzer runs through a cycle in which a measured volume
of sample is cooled in the analyzer cell. The freeze point is associated with the
temperature at which wax crystals disappear from a sample warming up from below
its freeze point. If the sample is hot initially, the cell cooling system may not be able
to bring the sample down to the freeze point temperature. So an important part of
the sample system is a chiller for the plant cooling water.
The following sample components are shown in Figure 800-23.
1. Sample Probe. The probe has a packing gland for extraction.
2. Root Valve. The ¾" gate valve is built to piping code. (By Field)
3. Local Sample Block Valve. This ½" SS ball valve is used to shut off sample at
the shelter for maintenance. (Whitey)
4. Sample Pump. This pump is needed due to variations in the process line pres-
sure. The pump bypass relief valve is set at 100 psig.
5. Sample Heat Exchanger is an initial sample cooler, using raw (not chilled) plant
cooling water.
5A. Fast Sample Loop Flow Indicator. This armored SS flowmeter with ½"
connections is used to indicate total flow. (Brooks, Wallace and Tiernan)
6. Temperature Indicator. This 2" dial thermometer with a 0-200°F. range gives
the sample temperature before entering the second heat exchanger. See component
11 below. (Ashcroft)
7. Pressure Gauge. The bypass pressure (0–100 psig) is needed when setting the
bypass flow using the valve described in component 19 below. (Ashcroft)
8. Bypass Filter. This filter with ½" connections and a 5 micron element handles
only the sample flowing to the analyzer. The fast loop acts as a flushing stream.
(Collins)

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Fig. 800-23 Freeze Point Analyzer Sample System (Courtesy of Precision Scientific Petroleum Instruments Co.)

9. Pressure Regulator. The pressure is regulated to meet the limits of the analyzer
cell. The SS regulator with ¼" connections has a range of 0–50 psig, set at 20 psig.
(GO, Fairchild)
10. Pressure Gauge. Range 0–50 psig. (Ashcroft)
11. Sample Heat Exchanger. The sample is cooled by chilled water from the
chiller. The analyzer inlet temperature limits are 50 to 120 deg F. If the freeze point
is very low the analyzer will be more reliable if the sample is cool.
12. Calibration System. The calibration of the analyzer may be checked using a
liquid standard which is introduced into the sample line from a cylinder pressurized
by plant nitrogen at 20 psig. If for any reason the sample lines or the sample cell
become coated with wax, a solvent can be introduced in the same way.
13. Sample Solenoid Valve. This valve is under the control of the analyzer which
allows the sample to flow through the cell to flush out the previous sample and to
warm the cell before the test sample is trapped.
14 & 15. Flowmeter and Valve. The sample flow rate through the analyzer is
controlled and indicated by this valve and flowmeter.
16. Level Switch. This switch is installed to provide an alarm when the level of the
collected sample is too high in the collection vessel, component 17 below.

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17. Collection Vessel. The sample is collected in this vessel for return to the line
under pressure. A manual drain valve can be used to lower the level in case of
emergency.
18 & 18A. Sample Return Pump. The pump is set at 500 cc/min. A low sample
flow is maintained into the vessel from the sample inlet line to provide a steady feed
for the pump. A pump is needed since the sample return is in the same line as the
take-off.
19, 20 & 21. The sample return flow is regulated and the pressure indicated by these
components.
22. The remainder of the sample system is designed to circulate cooling water
through the heat exchangers and the chiller. The design basis is for plant water at
50 psig and 65 to 80 deg F. The chiller can supply 2 gpm at 40 deg F.

Sulfur Plant Tail Gas Sample System: Excess H2S or H2S/SO2 Ratio (Ametek
Analyzer)
The biggest problem in handling this sample is avoiding drop-out of elemental
sulfur. The Ametek method mounts the analyzer above the sample take-off,
requiring a special platform. A demister section is installed vertically above the
take-off to allow sulfur particles to drop back into the line. The whole sample
system is steam jacketed and insulated, and the sample is drawn through the lines
and back into the process by a steam eductor.
The following sample components are shown in Figure 800-24.
1. Sample Lines. These lines are 1" jacketed pipe with connections for 65 psig
steam at 30 to 60 lbs/hr. They are kept as short as possible.
2. Sample Demister. A steam jacketed demister is designed to drop out elemental
sulfur. 65 psig steam requirements are 10 to 20 lb/hr. Demister temperature is
controlled at 260–265°F.
3. Demister Temperature Indicator. (Princo, Ashcroft)
4 & 6. Steam Jacketed Ball Valves. These 2" shutoff valves isolate the analyzer for
calibration and maintenance.
5. Steam Eductor. An eductor is more reliable than a pump for this type of sample
and keeps the sample temperature elevated. The eductor uses 90 to 110 lbs/hr of
65 psig steam regulated to 45 psig. (Part of the analyzer assembly)
7. Double Photometer Assembly. Two 400 series photometers are needed due to
overlap of the absorption bands of SO 2 and H2S. One photometer measures SO2, the
other measures SO2 + H2S. The H2S signal is separated in the electronics.
4620 Double Photometer Assembly. (Ametek)

Sulfur Plant Tail Gas sample system: Excess H2S, H2S/SO2 Ratio, or Air Demand
(Western Research)
The following sample components are shown in Figure 800-25.

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Fig. 800-24 Sulfur Plant Tail Gas Sample System: Excess H2S or H2S/SO2 Ratio (Courtesy of
Ametek)

1. Sample Probe. This probe is a custom design in 316 SS positioned in the center
of the tail gas line.
2. Sample Block Valves. These steam jacketed ball valves on both outlet and return
are heated to avoid condensation of sulfur and blockage of the lines.
3. Sample Lines. These lines are custom, electrically traced, flexible Teflon.
4. Sulfur Condenser. This exchanger is designed to condense sulfur and bypass it
to the return line before the sample is introduced into the analyzer cell. If sulfur
were not removed it would fog the optical windows and affect calibration.
5. Sample Cell. A single cell is sufficient in this system, since the absorption of
ultraviolet (UV) energy is measured at three wavelengths (see 9 below). The quartz
windows that allow the passage of the UV energy are accessible through screw-off
caps. Sample flow rate through the cell is 5 L/min with a velocity of 20 cm/sec.
6. Heated Sample Box. This box contains the sample cell, condenser, air aspirator,
air drive heater, and sample shut off valves. The temperature of the complete system
is maintained by thermistor sensors and a proportional controller. If any part of this
system fails, a back purge is automatically started, to prevent plugging in a cold
zone.
7. Sample Eductor. This eductor is a Teflon “jet pump” driven by heated air,
drawing the sample through the cell, exhausting the sulfur from the condenser, and
driving the sample in the return line.

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Fig. 800-25 Sulfur Plant Tail Gas Sample System: Excess H2S, H2S/SO2 Ratio, or Air Demand (Courtesy of Western
Research Div., Bon Valley Resource Services Ltd.)

8. Ultraviolet Lamp. This lamp is DC operated with high intensity at constant radi-
ation level for long-term stability.
9. Three UV Radiation Filters. These filters are rotated through the beam
emerging from the sample cell.
10. Photomultiplier Detector. This detector is sequentially exposed to three UV
wavelengths by the filter wheel. The electronic circuits transform the output signal
from the detector into an excess H2S, or “Air Demand” signal for the tail gas unit.
11. Pressure Regulator. The air supply is regulated for the eductor, zero air and
condenser.
12. Air Preheater. The air preheater for the eductor ensures that the sample temper-
ature is maintained.
13. Zero Calibration Valve. Zero adjustment is made with zero air in the sample
cell after all the sample has been flushed out of the cell. Gradual deterioration of the
UV source or deposits on the cell windows do not affect calibration due to the use
of a reference frequency method.
14. Air Eductor. This eductor is driven by heated air so that the sample will not be
cooled in the return line to the process. The eductor is needed to return the sample
back into the tail gas line because there is not enough differential pressure between
the take-off and return points.

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Hydrocarbon in H2S Sample System

The sample in this application is highly corrosive and toxic.
Special materials are required in all parts of the system in contact with the sample.
For example, ethylene propylene O-rings and seals are recommended for valves
etc., and teflon seals in ball valves. Provision is made for purging the sample system
with nitrogen before any break is made in the tubing for maintenance. The sample is
automatically shut off if the liquid in the knock-out pot reaches a high level.
The following sample components are shown in Figure 800-26.

Fig. 800-26 Hydrocarbon in H2S Sample System

1. Pressure Control Valve. The sample can be taken on either side of this pressure
control valve in the process line.
2. Sample Block Valves. These gate valves (usually ¾") are field installed gate
valves to piping code.
3. Local Block Valves. These manual ½" 316 SS ball valves with Teflon seals are
needed at the analyzer shelter to shut off the sample before purging the line for
maintenance. (Whitey)

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4. Heated Sample Line. The 1" sample line is heated to 125°F to prevent condensa-
tion in the line. The line is sloped back to the process line as a further precaution in
case of upsets. (Field installed)
5. Liquid Knock-out Pot. This pot is located at the lowest point in the sample
system and is drained back into the process line at least 8 feet downstream of the
take-off. This 304 SS pot has an internal volume of 2250 cc. (Integrated by analyzer
manufacturer)
6. Level Switch. This switch operates by sensing a high liquid level in the pot and
actuating an alarm. Sample is shut off to the analyzer by way of component 7. The
switch is an ultrasonic level sensor made by National Sonics.
7. Sample Shut-off Valve. This valve closes on high level in the knockout pot to
protect the analyzer against liquid that would seriously affect the calibration and
cause erratic readings. This ½" SS air operated ball valve with Teflon and EPR seals
is normally closed and will shut off on air failure. (Whitey)
8 & 9. Pressure Gauge and Regulating Valve. A bypass flow is required to reduce
sample lag time. The flow is adjusted to maintain at least 5 psig on the pressure
gauge. The ¼" SS valve has teflon seals (Whitey). The pressure gauge is a 0-30 psig
range and has a 4½" dial (Ashcroft).
10. Bypass Filter. This filter is considered the primary filter element, even though
the knock-out pot provides inertial filtering through the change in direction of the
gas flow. This filter also has liquid coalescing action. The bypass filter has a SS
body, 0.6 micron element, 1" bypass connections, and ¼" sample connections.
(Balston)
11. Differential Pressure Regulator and Regulating Valve. This flow control uses
a differential pressure regulator controlling the pressure across a restriction valve.
The 316 SS differential pressure regulator with Kynar has ¼" connections (Moore).
The ¼" SS valve has Teflon seals (Whitey).
12. Flow Indicator. The flow to the analyzer must be the same for calibration gases
and sample. The ¼" SS armored flowmeter has a range of 0.5–5 scfh (air) and
ethylene-propylene O-rings. (Brooks)
13. Final Filter. This ¼" SS inline filter has a 0.6 micron element. (Nupro)
14. Back Pressure Regulator. Since the sample must be returned to the line, a back
pressure regulator is required to maintain constant pressure on the analyzer cell, for
correct calibration.
The regulator has ¼" connections, SS and Teflon construction, and a range of
0–10 psig. (Go)
15. Solenoid Valves. The zero and span gases for calibration are introduced through
a block and bleed valve arrangement. (See also Figure 800-27). This type of
analyzer measures the absorption of infrared energy in a fixed volume gas cell. The
pressure in the cell during calibration must be the same as the sample when it is

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Fig. 800-27 Examples of Double Block and Bleed Valve Systems

being analyzed. These ¼" 3-way SS, 120 Volt, Class 1, Gp D, Div. 1 classification
valves have Buna-N O-rings. (Asco)
16. Sample/Calibration Gas Select Valve. This air operated, ¼", SS, 4-way ball
valve operates with the solenoids above.
17. Eductor. The ¾" 316 SS eductor draws the sample through the sample system
and the analyzer and returns it to the process line. (Penberthy)
18. Enclosure. The sample system components are mounted in an electrically
heated enclosure controlled at 120°F.
19. Auto Zero and Span Unit. This unit automatically adjusts the analyzer output
to the correct level when the calibration gases are introduced. It can actuate an alarm
when the adjustment exceeds a selected amount.
20. Check Valve. This valve safeguards the analyzer against steam back-up if there
is a blockage downstream of the eductor. The ½" SS check valve has a Teflon
coated spring and ethylene propylene O-rings. (Nupro)

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Examples of Double Block and Bleed Valve Arrangements for Analyzer

Sample Systems
An analyzer may monitor more than one stream and stream switching will normally
be automatic. Further, a single stream analyzer will very often be calibrated by a gas
or liquid which is introduced automatically by a timing device. In any of these
cases, if a simple block valve arrangement is installed, it is impossible to know if
one stream is contaminating another due to a leaky valve.
The best safeguard against cross contamination is to use a “double block and bleed”
valve arrangement. The name applies to any valve system which has a low pressure
bleed to drain, downstream of the first block in the non active stream and a second
block in the line taking the sample to the analyzer.
In a multi-stream system, a fast loop of each sample should be kept flowing continu-
ously near the analyzer, so that a fresh sample is always available at the stream
switching valve.
Examples of double block and bleed valve arrangements are shown in
Figure 800-27. The two systems on the left are for solenoid valves. There is one
system on the right for air operated valves, using common air actuators. It is shown
in two positions, one with the “sample” selected, the other with “span” selected. The
selected stream sweeps the line to the analyzer in each case. Leaks in the valves are
indicated by continuous flow through a bubbler or a flowmeter in the drain/vent
line. If the valves are not leaking, the flow will stop shortly after stream switching
has taken place.

Sample System for Gasoline Analyzers

This is a section of a sample system which is common to three gasoline analyzers,
having the same sample source and the same return line. The vapor pressure
analyzer shown in Figure 800-30 is a continuous flow model by ABB. The
minimum sample tubing size is ½", to maintain adequate sample flow through the
analyzer.
The following sample components are shown in Figure 800-28.
1. Shutoff Valve. The sample can be shut off locally from all of the analyzers by
this 1" SS ball valve. (Red-White)
2. Pressure Gauge. Common sample source pressure is indicated locally by this
0–400 psig gauge. (WIKA)
3. Bypass Filter. The sample take-off from the fast sample loop is through the side
branch of this ½" SS filter. (PermaPure)
4. Flowmeter. Fast sample loop flow is indicated on the meter. The flow can be
maintained when any or all of the analyzers are shut down and to reduce sample lag
time on start-up. The flowmeter has a range of 0–15 gpm and is armored. Flow rate
is set at 8 gpm. (Brooks)
5. Regulating Valve. Fast sample loop flow is regulated by this ¾" SS rising plug
valve. (Whitey)

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Fig. 800-28 Sample System for Gasoline Analyzers

6. Sample Shutoff Valve. This ½" SS ball valve isolates the sample system while
maintaining fast sample loop flow. (Red-White)
7. Flow Indicator. This meter indicates the cooling water flow through the sample
heat exchanger. The 3/8" SS flowmeter with a range of 0–3 gpm is set at 1.5 gpm.
(Brooks)
8. Cooling Water Flow Regulator. This is a ½" SS needle valve. (Whitey)
9. Sample Heat Exchanger. The sample temperature is controlled at 100°F in the
vapor pressure analyzer so the sample inlet temperature should be below 100°F.
(The heat exchanger is integrated by the analyzer systems manufacturer).
9A. Temperature Gauge. This ½" dial thermometer indicates the sample tempera-
ture at the outlet of the heat exchanger so that the cooling water flow rate can be
adjusted. (Princo)
10. Coalescing Filters. The ½" SS filters are installed in parallel, to allow for
changing of elements without disturbing the sample flow. (Balston)
11. Filter Bypass Valve. ¼" SS ball valve. (Whitey)
12. Bypass Flowmeter. The coalescing type of filter should have a continuous
bypass flow, to avoid accumulating water. The flow rate is adjusted to the minimum
required to keep the sample clear of water. The ¼" SS flowmeter with needle valve
and a range of 0–5.5 gph is set at set at 2 gph. (Brooks)

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13. Pressure Gauge. The pressure downstream of a filter is an indication of the

need to change the filter element. The gauge has a 2½" dial and a range of 0–300
psig. (WIKA)
14. Shutoff Valves. Each of the sample lines to the analyzers can be shut off inde-
pendently of the others using these ½" SS ball valves. (Red-White)
15. Check Valve. A check valve offers added protection against the sample flowing
back in a loop. The check valve is ½", 316 SS, and has a 1/3 psi spring. (Nupro)
16. Air Operated Valves. These ½" SS ball valves are operated remotely for a
variety of reasons to isolate the analyzer by shutting off the sample line both
upstream and downstream of the analyzer. (Whitey)
17. Sample/Calibrate Selection Valve. This manually operated, ½", 3-way ball
valve introduces a standard into the analyzer for calibration check. (Whitey)
18. Check Valve. A check valve protects against back flow if valve 17 is opened
when there is a failure of the calibration system pump. The valve is ½" and has a
1
/3 psi spring. (Nupro)
19. Valve. This ½" SS needle valve controls the flow through the vapor pressure
analyzer. (Whitey)
20. Valve. This ½" SS ball valve is operated together with valve 5 above when it is
necessary to maintain the fast sample loop flow while the sample to the analyzers is
blocked. (Red-White)
21 & 22. Check Valves and Block Valves. These valves are in the return lines from
the other gasoline analyzers. (Red-White)
23. Pressure Gauge. Return line sample pressure must be sufficient to keep the
sample flowing into the process line. The SS gauge has a 2½" dial and a range of
0–100 psig. (WIKA)

840 Analyzer Specification

Analyzer specifications not only help define instrument, utility, and shelter needs
but also provide a basis for comparing competing bids. Because process analyzer
requirements are very much application-dependent, certain additional documenta-
tion is required for a successful installation. The responsibility for providing the
documentation can be the Company’s, the integrator’s, or both. Responsibility is
also defined by whether or not the job is small and to be carried out in-house,
partially in-house, or turn-key.
The following annotated specifications, data sheets and forms are included in this
manual:
• ICM-MS-4362 Fabrication of Process Analyzer Systems
• ICM-DS-4362, Analyzer Enclosure Check-off Specification
• ICM-MS-4363 Installation of Process Analyzer Systems
• ICM-DG-4809 Process Analyzer Specification Sheets

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• EF-885 Analyzer Project Roles and Responsibilities

Bid Evaluation. Reviewing proposals or quotes from an acceptable integration shop
is no different from any other type of materials-management procedure. It is,
however, more complicated than placing an order for a field transmitter or a dial
thermometer because of the diverse aspects involved. You must write clear, rigorous
specifications and know the integrators and vendors.

841 Required Documents

Refer to the specifications for documents which are required from vendors, integra-
tors, and contractors. The following sections discuss additional documents that the
responsible engineer must fill out:

Analyzer Specification Sheets

Analyzer specification sheets are ISA-type forms that must be prepared for each
analyzer. The accuracy of each form is essential to the success of a project as an
unknown contaminant or an interfering component can render a sample system or
an analyzer useless.
Specification sheets contain information about the process conditions that deter-
mine both the analyzer selection and the sample system design. Number specifica-
tion sheets individually and sequentially and make certain that they contain
references to the applicable engineering flow diagrams and the requisition numbers.
A process specification that spells out the weight percentage of each component to
four decimal places may be totally useless unless the minimum and maximum
ranges possible during any type of operation (including upset, startup, shutdown,
and turnaround conditions) are listed and known to the designers. The temperature
and pressures of all streams must be obtained under all possible conditions. It is
very important to know if a component is in the liquid or gaseous phase or if it is at
the bubble point. To ensure that you have the information required, fill out an
analyzer specification sheet.

Acceptable Vendors and Integrators List

Compile a list of acceptable analyzer vendors alter considering the requirements for
each application. (This includes training and spare parts requirements.) Refer to the
analyzer selection section of this manual and discuss your selection with analyzer
specialists.
Note that analyzer installations usually have greater reason to justify single-sourcing
hardware based on the expense of spare parts and local maintenance training.

Additional Documentation for In-House Jobs

Instructions for Company in-house jobs require documentation and drawings for
both specification and construction group walk-throughs. Typical engineering job
instructions are included in Appendix E. Small jobs are often engineered in-house
and require the following documentation:

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Plot Plan. Include the location of the shelter, utilities. and sewers on an existing
plot plan or a sketch. Sewers may require separate drawings.
Analyzer House. Locate the analyzers, sample system components, and utility
headers on the house drawing(s).

Foundation Drawings
System Overview. Include the sample tap, return, fast loop, sample conditioning
plate or box, sample lines, data transmission, analyzer, maintenance recorder, and
operator readout devices. Locate all utilities and steam addition and traps on the
sample line.

Power and Signal Drawings

Cylinder Racks, Control Room or Analyzer Maintenance Room. As required,
these drawings are for boilermakers.
Sample Probe Sketch. Refer to the sketch in Appendix E.
Typical Engineering Job Instructions. The instructions can be modeled alter the
form in Appendix E.

842 Analyzer System Inspection and Acceptance Procedure

The following documentation is to be given to the Company at the acceptance test:
1. A copy of the final acceptance procedures. Given to the inspection representa-
tive by the system integrator six weeks prior to the test.
2. A general information sheet indicating the gases or liquids used to develop the
application and a copy of a calibration or liquid analysis used for calibration.
The original stream data is furnished by the Company representative.
3. A record showing 48 hours of uninterrupted operation on a calibration stan-
dard. This record should be fully documented with the time, date, chart speed.
range, sample size. flow temperature. and any available information to indicate
the conditions.

Performance
The analyzer assembly and operations are to be inspected. In the calibration stan-
dard, the systems assembler may or may not have all of the components listed in the
process stream data sheet, provided by the Company representative. The calibration
standard must contain components that are designated by an asterisk. The system
integrator warrants that the analyzer will perform within the required tolerances of
repeatability and accuracy on a sample, corresponding to the original Chevron
stream data. Performance is verified during the acceptance test. The company repre-
sentative observes the analyzer operations for eight continuous hours and is respon-
sible for conveying the information received at this test to the plant maintenance
file.

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Require that documentation of the 48-hour repeatability test be given to you in

advance of your visit.

843 Analyzer Shelters

The analyzer shelter can be three sided, fully enclosed, or free standing and is
assembled according to the systems diagrams and materials of construction
described in the specification. Normally, analyzers are mounted on wall racks,
except for those requiring all-around access. The system is assembled in such a way
that any one analyzer can be removed without interrupting the operation of the
others. All piping and tubing connections are made through bulkheads. The objec-
tives in providing an analyzer house are as follows:
• To create a space within an area that would be a nonhazardous area under
normal operating conditions to test or calibrate analyzers and perform mainte-
nance with opened casings and live electrical circuits. This space is achieved by
pressuring the shelter to lower the electrical classification and by limiting the
amount of hydrocarbon allowed to enter the shelter. This includes keeping
cylinders and sample conditioning outside the walls of the shelter whenever
possible.
• To create an environment in which analyzers and the ancillary equipment are
protected adequately from the weather and which provides a stable operating
temperature for the analyzer.
• To provide space for future equipment. Consolidating a number of analyzers in
the same building has the advantage of all-weather and multiple servicing.
Most installations allow multiple groupings. In a complex process unit, there
may be a number of groups strategically located.
Choose analyzer locations for the following reasons: accessibility; proximity to the
sample probe and utilities; and greatest possible distance from explosives and other
hazards. Technicians must be able to access the building. The locations must also be
near an unloading point for carrier gas, calibration gas cylinders, and equipment.
Grouping analyzers reduces costs as they share common instrument cable and
tubing trays.
See Figure 800-29 Analyzer Shelter Documentation for information that the inte-
grator provides for completing the Process Analyzer Specifications Sheet
(ICM-DS-4809).

Field Documentation
Complete the installation details of probes, sensors. and analyzer hardware located
in the field outside the analyzer shelter. Check for items in the following list:
1. Size and location of the first block valve and line identification
2. Location of sample tap hardware
3. Equipment support

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Fig. 800-29 Analyzer Shelter Documentation

Analyzer Shelter Documentation. The integrator should provide information concerning
the following:
• Outside dimensions of each shelter.
• Detail anchoring method.
• All piping, tubing, and electrical field connection points.
• Recommended lifting methods.
• Utility demand and requirements.
• Cable scheduling and tagging from the shelters to the control room.
• Ground bus location for field connection.
Company engineer should consider the location of the following equipment:
• Sample systems mounted on plates or in enclosures.
• Flare headers for sample returns.
• Vent headers.
• Steam headers and steam regulator.
• Drain headers.
• Block valves for sample, vent, and flare lines.
• Cylinder racks.
• Bulkheads.
• H2S Detectors if appropriate.
• O2 deficiency detector, to be considered.
• LEL sensor, to be considered.
Analyzer building inlet and outlet connections. These include samples, headers, utilities,
(water, steam, power, etc.) entering and leaving the building are to be consolidated in one
area. The tubing , pipe, and headers on the building walls should terminate at the most
convenient end of the building for final termination. Drain headers should be routed to the
proper underground drain. The goal is to be able to run one support for building installa-
tion connections.

4. Methods of attachment
5. Utility requirements and connection details
6. Signal and cable routing, schedule, tagging and connections details (The inte-
grator and the contractor coordinate incorporating this information on the
contractor’s routing drawings.)
Tag Information. To facilitate field installation, the integrator must tag all elements
of the analyzer system that are shipped as individual components or modules in
accordance with the sample system and the installation drawings.

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850 Analyzer Installation, Commissioning, and Startup

851 Analyzer Installation Checkout Procedure

The purpose of this procedure is to outline the methods for checking field-installed
analyzers. This procedure can be followed by contract personnel and Company
inspectors prior to continuity, loop, and leak checks (refer to ICM-MS-4363, Instal-
lation of Process Analyzer Systems).
Visually inspect all analyzers and accessories for damage alter installation. If
damage is observed, take corrective action. Each analyzer should have a sheet with
calibration and check -out data for every analyzer and analyzer loop that is
inspected.
Compare all analyzer installations against flow and installation drawings for proper
location and for compliance with any special provisions in these drawings.
Check that all analyzers are free of shipping restraints. Glass should be clean.
Temporary protective devices must be removed before startup. Verify that all
analyzers and tubing are correctly tagged, labeled, and installed at the correct loca-
tion.
All sample systems and sample probes must be tagged and checked for proper
installation with respect to the direction of flow, elevation, orientation, insertion,
and depth. Mount phenol material, 3 inches × 6 inches, on a bracket designed to
attach to the root valve piping, and post a warning to close the valve on the probe
(see the sample probe drawing in Appendix E).
Check analyzer wiring for circuit continuity. proper terminal connection, and labels.
Check analyzer piping and tubing which is process-connected for agreement with
P&ID’s and for appropriate materials, connection sizes, and rating. Verify that
adequate brackets and supports have been used to maintain rigid construction.
Verify the correct installation of all utilities. including proper steam addition and
trapping of prefabricated steam-traced bundles. Check the man- ufacturer’s engi-
neering data for these.
Do not commission sample lines until the process line has been flushed clean.
Isolate all analyzers from the process lines by blocking off or disconnecting them.
Clean the sample tubing lines thoroughly.
Ensure that all tubing connections are made according to the manufacturer’s recom-
mendation. Replace overtightened connections and tubing that is scarred by a tube
cutter or a knife used to remove the PVC jacket.

852 Analyzer Commissioning and Startup

These commissioning procedures provide the details for verifying the operability of
analyzer installations. Ensure that all checks, tests, and adjustments are conducted
by qualified analyzer personnel and verified by Company personnel.

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Leak Testing Instrument Utility Headers and Process Tubing. Perform a leak
test on the sample system and utility header. Test clean tubing, not hydrostatically
tested, with 100 psig instrument air and spray all fittings with a soapy. solution.
Close block valves and vent all analyzers. Remake, with new ferrules, all tube
fittings that leak alter one additional turn of the compression nut. Clean tubing for
GC support gases (helium, hydrogen, and air) with a volatile solvent and purge it
with nitrogen. Solvents, such as methylene chloride, have been used in the past.
Solvents, such as hexane, are not sufficiently volatile for cleaning purposes.
Turning Power on the Analyzer System. Check electrical terminations for conti-
nuity and location; verify the utilities; ensure that power is turned on by the party
responsible for the analyzer.

Analyzer Calibration Field Procedure

The process sample lines remain closed until after a calibration check of the
analyzer.
Documentation. A general information sheet is required that indicates the gases or
liquids used to develop the application and that gives an analysis report of the cali-
bration standard. Determine the appropriateness of the standard by using the correct
stream data from the Analyzer Specification Sheets. The analyzer technician fills
out the attached form for chromatograph checkout in the field.
Performance. Inspect the analyzer operation. The integrator may not have all the
components of the stream in the calibration standard. The calibration standard must
contain the components of interest and any possible interfering components. The
integrator must guarantee that the analyzer will correctly analyze a stream
containing the components which are outlined on the Analyzer Specification Sheets.
The prime contractor is responsible for field calibration, although he may delegate
the work to others. The analyzer shall show the same repeatability as in the factory
test. Refer to the Analyzer Startup Procedure in the Company’s data sheet
ICM-DS-4362

860 Calibration and Validation of Analyzer Output

861 Calibration
The only way to determine whether or not an analyzer is accurate when received is
to check it against a series of calibration standards. After this initial calibration, the
analyzer must be checked periodically against at least one suitable standard to
ensure continued accuracy. Specification of calibration standards are discussed in
ICM-MS-4362. This specification considers the limitations of the external standard
method and the normalization method.

Weight Versus Volume Basis

Almost all analyzers can provide direct results on a molar or volume basis, because
a fixed volume of sample is actually analyzed. If sample density is not constant,

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inaccuracies can occur. Normalization allows for calculations on a weight basis. If

sample density is constant, calculations by both weight and volume are possible.

External Standard Method

The calibration and validation of analyzer output is obtained with the external stan-
dard method and can be applied to most analyzers. Analysis can be determined on a
volume basis only when the sample density is constant. For photometric analyzers,
both a span and a zero standard are required.

Normalization Method
In this method, normally only for chromatographs, each peak area is corrected for
normal variations in detector response. The results can be determined on a weight or
a volume basis. All components must be measured, however, the sample size is rela-
tively unimportant.

862 Continuous Validation of Analyzer Output

Continuous validation of analyzer output is required for closed-loop control. The
validation can be internal and/or external via switches and relays that are added by
the user. An example of analyzer integrity is provided in Figure 800-30. In
Appendix E there is an electrical loop drawing of an analyzer system with pressure
alarm.
Errors are detected by failed function at the analyzer or its controller. At the DCS or
host computer, such errors are classified in a programmable hierarchy so that the
control system can take appropriate response. Some error functions may only be
diagnostic in nature, while others (caution, warning, and error) indicate an inaccu-
rate analysis.
At present, because vendors have systems with various options and users require
different configurations. it is advisable to consult with process control and process
analyzer experts and with the vendors to determine where alarms should be classi-
fied in the hierarchy.
Serial Communication check. In digital data transmission, there is a possibility
that one or more bits of a digital number may be in error. Commonly, errors are
checked by using parity. An extra bit, such as an ASCII character, added to a binary
word is set on or off to achieve an even or an odd parity. If a bit in the binary word
is dropped or incorrect, the total number of bits is checked. This is not a fool-proof
method because more than one bit may be dropped or be incorrectly high.
If the checksum method is used (where a sum is transmitted by a block of charac-
ters), the receiving device then sums the characters and compares the sum with the
received checksum. If the two do not agree, the entire transmission block is rejected.
Analyzer self validation check. Analyzers can be designed to flag errors in temper-
ature, drift, and carrier pressure. These checks are outlined for chromatographs in
ICM-MS-4362. Self-validation checks are also available for other analyzers. It is
preferable that such signals form a common alarm to the computer (good/bad).

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Fig. 800-30 Analyzer Integrity Example — Boiling Point Analyzer

Sample system check. Usually, sample-system check is limited to sample flow in

the fast sample circulation loop and in the slipstream to the analyzer. Such checks
are necessary for exceedingly dirty streams or in applications so critical that daily
checks by an analyzer technician are insufficient. Sample flow shut-off is likely to
affect composition in the percent level very quickly and is easily detected by manip-
ulation of computer controller data. You must consider if this will guarantee the
necessary validation.
Computer controller data manipulation. The system computer that accepts the
analyzer signal can check its validity. Integrity checks include minimum or
maximum rate of change of signal and analyzer out of range (high/low limit).
See Analyzer Output Integrity Checks in Figure 800-31..

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Fig. 800-31 Analyzer Output Integrity Checks

Process chromatographs should have the following • Chip failure.
internal integrity checks. • Any undefined table reference.
• Detector balance greater than limit - Balance
required to zero detector is greater than instru- • Invalid data type, analog or digital.
ments limit. • I/O errors.
• Temperature deviation exceeded. • Power failure.
• Low carrier pressure. Oxygen Analyzers
• Low sample pressure. Oxygen analyzers used for furnace control require
special error warning message to ensure proper oper-
• Peak outside concentration limit. ation of furnaces. There are extractive type analyzers
• Purge failure. and close coupled as well as in situ (zirconium)
• Oven shutdown. analyzers used in this service.

• Any insufficient memory problem in programmer Signals required include:

tables. • Instrument in calibration.
• No access to analyzer data highway. • Calibration failure.
• Host computer interface does not respond. • Instrument in “blow-back” mode.
• Message transmission failure on data highway. • Cell temperature out of range (zirconium
• No stream selected at cycle start. analyzers).

• Detector flame out. • Cell failure (zirconium).

• Detector balance greater than limit. • Furnace shut down / flame out.

• Detector zero greater than limit. • Power failure.

• Peak retention drift. • Sample flow or pressure (extractive type).

• Analog to digital converter failure. Typical oxygen sample systems with integrity checks
are contained in Section 830.
• Any programming error, i.e. gates overlap or too
many gates. Other Analyzers
In critical control applications the analyzers will
• Number of gates on does not match number of require the following signals where applicable.
gates off.
• Cell failure.
• Tables unavailable.
• Low sample pressure at analyzer inlet or low flow.
• Any failed signal i.e. failure to signal balance to
detector board. • Calibration.

• Numeric value found where string expected and • Loss of power.

vice versa. • Loss of enclosure purge.
• Total area change outside limit. • Failure to calibrate.
• Failure to reset cycle.
• Any queue, peak, or arithmetic overflow.
• Invalid address.
• Failure of component to respond.

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870 Safety

871 General
Consider the safety of operating and maintenance personnel when designing an
analyzer installation. Several safety items have already been discussed: observing
proper metallurgy in choosing sample system piping, providing relief valves to
prevent overpressuring, and providing drain valves for relieving system pressure
prior to performing maintenance.
Safety considerations discussed in this section are sample line installation. sample
disposal problems, and electrical ignition problems in sample piping and analyzer
areas.

872 Sample Line and Sample System Components

Ensure that sample lines and all connections to sample system components are leak-
proof and that small piping is seal welded. Select tubing and tubing fittings (consid-
ered more reliable) wherever possible. Where pumps are required in the sampling
system, provide a means for collecting and disposing of possible leakage. Where an
air supply is available, install air-driven rather than electrically driven pumps to
increase sample pressure or to handle sample disposal with a minimal hazard from
malfunctioning.
To protect personnel, leak proof and insulate or isolate hot sample lines. Locate
outside analyzer shelters outside all high-pressure, high-temperature, and high-
volume sample loops that reduce time lag, along with their associated pumps, filters.
rotameters, and heat exchangers. Select 1/8-inch or ¼-inch stainless steel tubing for
sample lines entering the analyzer shelter. More exotic alloys may be required in
some applications involving highly corrosive service. Closed-couple all sample-
system components inside the analyzer enclosure to minimize sample volume and
locate them in a sample system housing that can be purged to reduce the possibility
of an explosion in the event of a leak. Check pressure/temperature ratings of each
component and operate at 85 percent or less. Some locations require certification by
a nationally recognized testing agency (UL or FM)

873 Leak Detection

Due to the large number of small fittings, the risk of leaks is high. Ensure that
enclosed sample systems handling hazardous material (such as H2S) have leak-
detection systems that warn the operator or maintenance worker of leaks before he
or she opens the enclosure. This warning can range from H2S paper at a vent
opening to tieing into an existing remote, leak-detection system.

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874 Sample Disposal System

Gas and Vapor
Some sample system installations do not have sufficient pressure drop available to
allow sample return to the process without the addition of a pump or some other
means of sample disposal. In most locations, it is not acceptable practice to
discharge small amounts of light hydrocarbon vapors to the atmosphere. Venting
requires the necessary piping to bring vented hydrocarbons to a safe location. For
example, because most chromatographs are sensitive to backpressure in the vent
lines, the vent line size should be large enough so that vented sample flow cannot
result in a buildup of backpressure. GC carrier gas vents are still acceptable as long
as they are piped outside the analyzer shelter.
Future installations face more stringent environmental requirements governing the
allowable amount of effluent vented to the atmosphere. Means of sample disposal
will include relief lines. furnaces, or return to the process. If such an installation is
required, take the precautions necessary to eliminate the potential backpressure of a
closed system. If sample disposal is made in a furnace, provide a means to shut the
vent automatically in case the furnace is shut down. This arrangement eliminates
venting hydrocarbons into the furnace while maintenance personnel are working on
the furnace.

Liquid
Liquid drains for analyzers are two-inch (minimum) pipes sloped to an oil sewer.
Vent the high point of this drain line to the atmosphere as described above for vent
lines. Do not allow valves or goosenecks in drain lines as they might create liquid
seals. Heavy components being sampled might solidify in the drain line at atmo-
spheric temperature, therefore, it may be necessary to steam trace or electrically
trace and insulate the drain line.

875 Electrical and Ignition Problems

Sample systems and sample-system components include electrical components,
such as motors, electrical heat tracing, solenoid valves. and pressure switches. It is
necessary. therefore. to be familiar with the electrical classification of the installa-
tion area and to select the proper location, material, and equipment consistent with
the classification. The analyzers (and some of their associated sampling system
components carrying hydrocarbons) will be located in cases or enclosures that may
also contain analyzer electrical equipment. The National Electric Code defines
conditions for specific classifications. Refer to Section 300 of the Electrical Manual
for a more detailed discussion on area classification. Place the analyzer in a nonhaz-
ardous area. If this is not possible, build the analyzer or hazardous portions of it into
explosion-proof housing to allow safe operation in Class 1, Group C&D, Division 1,
areas. If such an installation has been made, explain to the operating and mainte-
nance personnel that there is a possibility of unsafe conclusions existing during
maintenance and calibration. These conditions are related to opening explosion-
proof housings and exposing electrical and electronic elements while they are oper-
ating. Obviously, soldering components and other hot work cannot be carried out in

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areas where hydrocarbons are present without a special hot work permit. If such
conditions exist, remove the analyzer or the faulty unit. Moreover, it should be
understood that precautions must be taken when removing and replacing explosion-
proof housing covers and conduit covers.
Screwed or flanged-type, explosion-proof housings require constant attention if they
are to remain safe. For example, the explosion-proof cover is safe only for as long
as all the bolts of a flange-type cover are installed and tightened properly. If mainte-
nance tightens only half the bolts, the housing can no longer contain an explosion. If
the cover is dropped, corrodes, or if the smooth mating surface is damaged, it is
probably no longer safe.
Purging an enclosure following the requirements of NFPA 496 is another way to
protect electronic equipment. Section 9 of this bulletin refers specifically to
analyzers and analyzer shelters.
Intrinsically safe electrical systems have become popular recently because of their
convenience and the savings in the initial equipment costs and in installation costs.
(See Section 1400 of this manual for a more detailed discussion on intrinsic safety.)
Equipment that is intrinsically safe can be maintained conveniently as heavy covers
are not required to be in place when the equipment is in operation. Calibration
checks and adjustments can be made safely in the field without special precautions
even though the equipment is installed in a Division 1 area.
In conclusion, safety for operating and maintenance personnel in hazardous areas
can be obtained by:
1. Containing a hazardous device in an approved enclosure (explosion proof for
Division 1 areas; hermetically sealed for Division 2 areas).
2. Changing the nature of the atmosphere surrounding the source of ignition by
providing a forced ventilation system.
3. Installing of the hazardous device in an isolated, non-hazardous area.
4. Removing the source of ignition with intrinsically safe circuit designs.

880 References
For further information consult with local maintenance personnel, engineers,
vendors, and analyzer specialists in CRTC’s M&CS Unit. The following list of
references will also be of help:
1. Process Analyzer Technology. John Wiley and Sons, 1986.
2. On-Line Process Analyzers, Wiley Interscience, 1988.
3. Principles of Sample Handling and Sampling Systems Design for Process Anal-
ysis. ISA,1972.
4. The Design and Application of Process Analyzer Systems. Wiley Interscience,
1984.

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5. General Handbook of On-line Process Analyzers. Ellis-Horwood, 198 1.

6. Gas Chromatographs as Industrial Process Analyzers. Pergamon Press, 1911,
7. Sampling Systems for Process Analyzers. Butterworths, 1981.
8. Quality Measuring Instruments in On-Line Process Analysis. Ellis- Horwood,
1982.
9. pH Control. ISA, 1984.
10. API RP 555, Process Analyzers
11. ANADATA. Measurementation.
12. ISA Directory.
13. Intech, ISA.
14. Instrumentation and Control Systems. Chilton.
15. Refinery Analyzer Applications Reference Document, CRTC, 1996.
16. Analytical Instrumentation. Chilton Book Co., 1994.

Chevron Corporation 800-83 July 1999