Engineering Standard
SAES-J-510
1 January 2018
Process Analyzer Systems
Document Responsibility: Instrumentation Standards Committee
Contents
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Scope .......................................................2
Conflicts and Deviations.............................2
References ...............................................2
Definitions .................................................4
General Requirements ...............................7
Electrical Requirements .............................8
Sample Systems ..................................... 11
Tubes and Tube Fittings .......................... 21
Sample Recovery Systems ...................... 23
3-Sided Shelter ....................................... 24
Analyzer Cabinet Design.......................... 26
Walk-In Analyzer Shelters ........................ 31
Headers and Vents .................................. 39
Calibration and Gas Cylinders Racks ........ 40
Combustible Gas / Toxic Gas /
Oxygen Detection ................................ 41
16 Sour Service Applications ........................ 42
17 Inspection ............................................... 43
18 Packing/Shipping/Storage ........................ 43
19 Documentation ........................................ 44
Revision Summary .......................................... 45
Previous Issue Date: 15 September 2016
Next Planned Update: 15 September 2019
Revised paragraphs are indicated in the right margin
Contact: David Tamez (tamezdx) on phone +966-013-8801345
©Saudi Aramco 2018. All rights reserved.
Page 1 of 45
Document Responsibility: Instrumentation Standards Committee
Issue Date: 1 January 2018
Next Planned Update: 15 September 2019
1
SAES-J-510
Process Analyzer Systems
Scope
This standard describes the minimum mandatory design and installation requirements
related to analyzer sample points, analyzer sample transport systems, sample
conditioning systems, analyzer shelters, analyzer cabinets, 3-sided analyzer shelter, and
safety systems related to online process analyzer measurement systems.
2
Conflicts and Deviations
Any conflicts between this document and other applicable Mandatory Saudi Aramco
Engineering Requirements (MSAERs) shall be addressed to the EK&RD Coordinator.
Any deviation from the requirements herein shall follow internal company procedure
SAEP-302.
3
References
The selection of material and equipment, and the design, construction, maintenance, and
repair of equipment and facilities covered by this standard shall comply with the latest
edition of the references below, unless otherwise noted.
3.1
Saudi Aramco References
Saudi Aramco Engineering Procedure
SAEP-302
Waiver of a Mandatory Saudi Aramco Engineering
Requirement
Saudi Aramco Engineering Standards
SAES-A-112
Meteorological and Seismic Design Data
SAES-B-054
Access, Egress, and Materials Handling for Plant
Facilities
SAES-B-068
Electrical Area Classification
SAES-J-002
Technically Acceptable Instruments
SAES-J-003
Instrumentation-Basic Design Criteria
SAES-J-505
Combustible Gas and Hydrogen Sulfide in Air
Detection Systems
SAES-J-902
Electrical System for Instrumentation
SAES-J-903
Intrinsically Safe Systems
SAES-N-001
Basic Criteria, Industrial Insulation
Page 2 of 45
Document Responsibility: Instrumentation Standards Committee
Issue Date: 1 January 2018
Next Planned Update: 15 September 2019
SAES-J-510
Process Analyzer Systems
SAES-P-100
Basic Power System Design Criteria
SAES-P-104
Wiring Methods and Materials
SAES-P-111
Grounding
SAES-P-116
Switchgear and Control Equipment
SAES-P-123
Lighting
SAES-W-011
Welding Requirements for On-Plot Piping
Saudi Aramco Materials System Specifications
3.2
12-SAMSS-014
Pre-Engineered Metal Buildings
16-SAMSS-518
Low Voltage Panelboards
34-SAMSS-510
Online Analyzers
34-SAMSS-514
Combustible Gas and Hydrogen Sulfide Monitor
Industry Codes and Standards
American National Standards Institute
ANSI Z97.1
Safety Glazing Material Used in Buildings
American Petroleum Institute
API RP 555
Process Analyzers
American Society for Testing and Materials
ASTM A269
Standard Specification for Seamless and Welded
Austenitic Stainless Steel Tubing for General
Service
American Society of Mechanical Engineers
ASME B31.3
Process Piping
ASME PTC 19.3
TW-2010
Thermal Well Design Standard
International Electrotechnical Commission
IEC 60079-0
Explosive Atmospheres - Part 0: Equipment General Requirements
National Association of Corrosion Engineers
NACE MR0175/ISO 15156
Petroleum and Natural Gas Industries –
Materials for Use in H2S Containing
Environments in Oil and Gas Production
Page 3 of 45
Document Responsibility: Instrumentation Standards Committee
Issue Date: 1 January 2018
Next Planned Update: 15 September 2019
SAES-J-510
Process Analyzer Systems
National Electrical Manufacturers Association
NEMA ICS 6
Enclosures for Industrial Controls and Systems
National Fire Protection Agency
4
NFPA 70
National Electrical Code (NEC)
NFPA 496
Purged and Pressurized Enclosures for Electrical
Equipment in Hazardous (Classified) Areas
Definitions
Analyzer Cabinet: An upright prefabricated enclosed non-walk-in structure that
provides environmental protection and climate control for a single process analyzer.
Analyzer maintenance is performed while standing on the outside of the structure with
the doors open. The analyzer cabinet system is not designed for personnel entry.
Analyzer cabinets should not be confused with terminal strip junction boxes or analyzer
enclosures.
Analyzer Enclosures: Are used for protecting analyzer circuit boards and detection
hardware. These enclosures are normally attached to wall supports, panels, or
instrument stands.
Analyzer Manufacturer: Analyzer company that manufactures, supplies, provides, or
builds, certified process analytical measurement devices.
3-Sided Analyzer Shelter (sunshade): A prefabricated structured roof and wall
system that has one open side; which protects process analyzer equipment from direct
sunlight exposure and allows natural air ventilation for equipment cooling.
Analyzer Shelter: Analyzer shelters are prefabricated unmanned walk-in structures
that provide protection for complex and semi-complex process analyzers systems.
Analyzer shelters provide environmental protection against extreme ambient
temperatures, dust contamination, and corrosive environments. Analyzers shelters
provide humidity and climate control for sensitive process analyzer electronic equipment.
Analyzer Slip Stream: The sample stream flow between the sample conditioning
system and the analyzer sample inlet port.
Analyzer System Integrator: Company or vendor that provides pre-packaged analyzer
designs and engineering services; builds and provides pre-packaged analytical systems.
Asphyxiant: Asphyxiant is a substance that can cause unconsciousness or suffocation due
to displacement or depletion of oxygen concentration in breathing air (e.g., nitrogen, carbon
dioxide, etc.)
Page 4 of 45
Document Responsibility: Instrumentation Standards Committee
Issue Date: 1 January 2018
Next Planned Update: 15 September 2019
SAES-J-510
Process Analyzer Systems
Conventional Gas Chromatograph: A chromatograph that is designed to operate in a
climate controlled environment.
Critical Instrumentation: Critical Instrumentation is defined as a system, upon loss of
power, would cause: (1) a process failure that is not fail-safe, (2) area or plant
shutdown, (3) loss of custody transfer metering or accounting system, or (4) other
adverse facility operating scenarios. Such systems shall include, but not be limited to:
ESD systems, gas detection systems, process heater safety, critical process monitoring
and control; and custody transfer metering systems.
Dead Leg: Sections of pipe or tubing that, by design, do not allow for the flow of
material through them.
Fast Loop: High velocity, continuously operation sample loop bringing fresh sample
in close proximity to the analyzer sampling conditioning system. Fast loop may also be
referred to as bypass loop or bypass stream.
Field Mounted Analyzer: Process analyzers that are designed for outdoor use and are
certified for high ambient temperature environments. Field mounted analyzers do not
require climate or humidity control environments.
Field Mounted Gas Chromatograph: A chromatograph that is designed and certified
to operate in outdoor environments.
Packaged Systems: Systems developed and manufactured by a Analyzer System
Integrator. Systems may include but not limited to analyzer shelters, analyzer cabinets,
sunshades, sample conditioning systems, cylinder racks, and other ancillary analyzer
equipment.
Process Analyzer: A measuring device that determines the intrinsic property of a
material and/or concentration of one or more chemical compounds in the presence of
other chemical compounds.
Process Analyzer, Complex: Process analyzers that are complicated in nature, which
are extremely sensitive to environmental heat, humidity, dust contamination, corrosion,
and require climate control and humidity control. Such analyzers require tight
temperature control (climate control) for proper electronic heat dissipation, require a
high level of troubleshooting skills, and require highly intrusive maintenance activities.
(e.g., conventional gas chromatographs, mass spectrometers, physical properties
analyzers, continues emission monitors (CEMS), Fourier Transform (FTNIR), etc.)
Process Analyzer, Semi Complex: Process analyzers that are sensitive to
environmental conditions and require climate control for heat dissipation and require
some level of intrusive maintenance activity. (e.g., infrared, UV, SRU tail gas,
mercury, total carbon analyzers, wet chemistry analyzers, etc.)
Page 5 of 45
Document Responsibility: Instrumentation Standards Committee
Issue Date: 1 January 2018
Next Planned Update: 15 September 2019
SAES-J-510
Process Analyzer Systems
Process Analyzer, Simple: Process analyzers that are simplistic in nature that require
minimal non-intrusive maintenance activities and are normally designed for direct field
mounting. (e.g., pH, conductivity, ORP, ion-selective probes, etc.)
Process Line: The piping used to transport of process fluids (other than sample lines).
Representative Sample: A portion extracted from total volume that contains the
constituents in the same proportion that are present in the total volume.
Remote Cylinder Rack: A cylinder rack system used for storing carrier gases and/or
calibration cylinders that is normally located away from the analyzer shelter or analyzer
cabinet.
Sample Probe: A sampling device in the form of a special tube or pipe assembly or
flanged probe that is inserted in a defined location into the process stream. The probe is
used to continuously extract a small portion of process medium as sample.
Sample Conditioning System: A system which prepares a portion of the sample from
the sample transport system to be compatible with the analyzer requirements.
This enables the analyzer to reliably perform its analytical measurement/determination
unattended.
Sample Pre-Conditioning: A system that consists of one or more devices that
condition the sample (pressure, temperature, flow or change of state) so that is
transportable to the sample conditioning system.
Sample Line: The tube used to transport continuous process sample from sample
probe to the analyzer sample conditioning system.
Sample Point: The location where the sample is extracted from process line. It may
also be referred to as sample nozzle or process tap location.
Sample Recovery Systems: A custom built system that provides the means to recover
process samples or reclaim analysis byproducts from process analyzers and returns it
back to the process or other containment system.
Toxic Gas: Gaseous substances that, if released in an area, will cause a health hazard
by contact with the skin or by inhalation from the surrounding atmosphere.
Examples of toxic gas include but not limited to carbon monoxide (CO), carbon dioxide
(CO2), sulfur dioxide (SO2), chlorine (CL2), ammonia (NH3), hydrogen chloride (HCL),
hydrogen sulfide (H2S), and others.
Page 6 of 45
Document Responsibility: Instrumentation Standards Committee
Issue Date: 1 January 2018
Next Planned Update: 15 September 2019
5
SAES-J-510
Process Analyzer Systems
General Requirements
5.1
Packaged Equipment Requirements
5.1.1
The package systems shall be supplied as completely assembled
systems suitable for direct mounting in a process plant.
5.1.2
All analyzers shall be supplied per Saudi Aramco Regulated Vendors
List.
5.1.3
No equipment other than process analyzers and analyzer ancillary
equipment shall be mounted in analyzer shelters, analyzers cabinets, or
under analyzer sunshades. Installation of non-related process analyzer
equipment in shelters is not permitted.
5.1.4
Analyzers shall be single-stream analyzers. Multi-stream gas
chromatograph analyzers will be considered only if the conditions listed
in 34-SAMSS-510 Section 5.2 are applicable.
5.1.5
Stream switching in liquid phase services is prohibited.
5.1.6
All equipment including wiring, tubing, and supports shall be installed in
such a manner that it will not interfere with the operation, maintenance,
or removal of sample system hardware, analyzers, or other ancillary
items.
5.1.7
The top elevation of a sample conditioning systems, analyzers, or any
other high maintenance items shall not exceed 1.8 m (6 ft) in height
from the grade elevation.
5.1.8
Field connections for shelters and analyzer cabinet internal wiring shall
terminate at externally mounted analog or digital junction boxes.
Junction boxes shall be kept to a minimum and shall be mounted at
elevations above higher maintenance equipment.
5.1.9
Sample conditioning systems and calibration cylinders mounted outside
of analyzer shelters and analyzer cabinets shall be protected with an
overhead sunshield.
5.1.10 Field connections for shelters and analyzer cabinet piping or tubing
shall terminate at the bulkhead connections or pipe flanges.
5.2
Environmental Requirements
Analyzers and ancillary equipment shall be suitable for installation in the
applicable environmental conditions specified in SAES-J-003 and shall be
Page 7 of 45
Document Responsibility: Instrumentation Standards Committee
Issue Date: 1 January 2018
Next Planned Update: 15 September 2019
SAES-J-510
Process Analyzer Systems
designed for contaminant levels specified in Ambient Air Quality section of
SAES-A-112.
6
Electrical Requirements
6.1
6.2
General Requirements
6.1.1
Electrical systems shall be designed and installed in accordance with
NFPA 70 National Electrical Code and SAES-P-100.
6.1.2
All electrical and electronic equipment in hazardous areas shall meet
listing/certification requirements specified in this document and the NEC.
6.1.3
Process analyzers shall be powered by a non-UPS system unless the
analyzers or analyzer ancillary equipment is identified as Critical
Instrumentation as defined in Section 4. Analyzer equipment defined as
Critical Instrumentation shall be powered by a UPS system.
6.1.4
Electric panelboards shall be mounted outside the shelter or analyzer
cabinet systems.
6.1.5
Installation of analyzer wiring systems shall meet requirements
specified in SAES-J-902.
Area Classification
6.2.1
Shelters, analyzer cabinets, sample conditioning systems, and ancillary
equipment shall be classified in accordance with SAES-B-068,
Electrical Area Classification.
6.2.2
Analyzer shelters, analyzer cabinets, process analyzers, and ancillary
analyzer equipment designed for non-flammable or non-toxic samples
and are designed for general purpose use; such equipment shall be
located only in non-classified areas.
6.2.3
Analyzer shelters, analyzer cabinets, process analyzers and ancillary
analyzer equipment located in hazardous areas and/or analyze
flammable or toxic samples shall be suitable for use in the electrical
classified area in which they are installed; but at minimum shall be
certified for use in a Class 1, Zone 2 hazardous area and for the gas
groups and temperature class appropriate to the materials handled
within the area.
Commentary Note:
When hydrogen is introduced within the shelter as a carrier gas, the
equipment internal to the shelter does not have to be certified to gas
Page 8 of 45
Document Responsibility: Instrumentation Standards Committee
Issue Date: 1 January 2018
Next Planned Update: 15 September 2019
SAES-J-510
Process Analyzer Systems
group B or IIB + Hydrogen, provided that hydrogen supply line has a built
in orifice or flow limiting device, an LEL detector is placed inside the
upper region of the shelter atmosphere to detect any abnormal release,
and the shelter is equipped with an auxiliary ventilation fan that
automatically starts upon detection of LEL gas.
6.3
Equipment Certification
Equipment used in a hazardous location shall be labeled, listed or certified as
required by SAES-P-100.
6.4
6.5
Electrical Protection Design
6.4.1
All instrument enclosures and junction boxes shall be third party
certified. Self-certification is not acceptable.
6.4.2
Enclosures for instruments and field junction boxes in outdoor plant
areas shall be in compliance with SAES-J-902.
6.4.3
Intrinsically Safe Systems shall only be used where other methods of
protection are impractical. Intrinsically Safe Systems when required
shall meet the requirements for P&CSD review of the design, system
certification, and installation listed in SAES-J-903.
Equipment Purging
The enclosures of analyzers containing sources of flammable gases or vapors
shall be equipped with a Type Z pressurization system in accordance with
NFPA 496. Purged analyzers shall be approved by one of the following
certification bodies: UL, FM, CSA, CENELEC or IECEx.
6.6
6.7
Grounding
6.6.1
Analyzer shelters, analyzer cabinets, 3-sided sunshades, process
analyzers, and ancillary analyzer equipment shall be grounded in
accordance with SAES-P-111 and SAES-J-902.
6.6.2
Intrinsically Safe Systems shall be grounded in accordance with
certification requirements and SAES-J-903.
Power and Wiring Methods
6.7.1
Panelboards shall be selected, designed, and installed in accordance
with 16-SAMSS-518 and SAES-P-116.
6.7.2
All on/off power switches shall be provided with lockout provisions or
lockout hole for padlock installation. On/Off power switches shall be
Page 9 of 45
Document Responsibility: Instrumentation Standards Committee
Issue Date: 1 January 2018
Next Planned Update: 15 September 2019
SAES-J-510
Process Analyzer Systems
provided for analyzers, lighting fixtures, and other ancillary equipment
requiring power isolation. On/Off power switches shall be located next
to the analyzer.
6.7.3
Analyzer power and service power supplies shall be designed and
installed in accordance with SAES-P-104. Motors, motor control
equipment, and panelboards shall be mounted outside the shelter or
analyzer cabinet.
6.7.4
Instrument wiring systems shall be designed and installed in accordance
with SAES-J-902.
Commentary Note:
SAES-J-902 does not apply to the internal wiring requirements for
analyzers or analyzer accessories.
6.7.5
Analog and digital signal wiring shall terminate on external junction
boxes located on the exterior wall of the analyzer shelter or analyzer
cabinet.
6.7.6
Power supply wiring from the power panel to the analyzer shall
terminate at the analyzer on/off power switch.
6.7.7
Separate enclosures shall be provided for analog, digital, and instrument
power supplies. Wiring shall be segregated in accordance with
SAES-J-902 and shall be clearly labeled.
6.7.8
Power cables, communication signals, signal wires, wiring, etc.,
entering analyzer shelters, or analyzer cabinets shall utilize a recessed
bulkhead plate or multi-cable transit (MCT) system.
6.7.9
Conduit if used shall penetrate shelter or cabinet walls through recessed
bulkhead plates and shall use a conduit seal fittings located immediately
outside the shelter or cabinet bulkhead plate. Conduit seal fittings shall
be sealed with sealing compound in accordance with SAES-J-902
Section 6 requirements.
6.7.10 Armored cables if used shall sealed with cables glands at the analyzer,
panelboard, and signal junction box locations. Cable glands shall be
installed in accordance with SAES-J-902 Section 6 requirements.
6.8
Communications Equipment
Install all network communication devices associated with the analyzers (fiber
optic hubs, fiber optic WIC boxes, Ethernet hubs, data net hubs, etc.) inside
analyzer shelter or analyzer cabinet.
Page 10 of 45
Document Responsibility: Instrumentation Standards Committee
Issue Date: 1 January 2018
Next Planned Update: 15 September 2019
7
SAES-J-510
Process Analyzer Systems
Sample Systems
Sample conditioning systems shall be designed to deliver a representative sample at a
temperature, pressure, flow, and dew point consistent with the analyzer manufacture
requirements. The Analyzer System Integrator shall guarantee the performance of the
sample conditioning system under normal, start up, and process upset conditions and as
specified in relevant analyzer specification sheet.
7.1
Sample Taps and Sample Probes
7.1.1
Sample probes shall be used in process analyzer applications.
Probes shall be installed in locations that provide representative samples
from process streams.
7.1.2
Sample taps located on dead legs are not permitted.
7.1.3
The sample tap process isolation valve shall be located where the
process time lapse is minimum under the conditions compatible with the
operation of the analyzer.
7.1.4
The mechanical design and construction of the sample taps shall comply
with process piping codes.
7.1.5
Sample probes shall only be installed on process lines with line
diameters 101 mm (4 in) and above.
7.1.6
Flanged all welded sample probes shall be used for all processes
containing hydrocarbons, sour and toxic components.
7.1.7
Retractable probes shall be shall not be used in hydrocarbon, sour, or
toxic services.
7.1.8
Retractable probes may be used in applications such as furnaces,
boilers, thermal oxidizers, flue stacks, tanks, continuous monitoring
systems (CEMS), or process lines that vent to the atmosphere, operate at
or near atmospheric pressure, or negative draft pressures.
7.1.9
Sample probes shall protrude into the process line approximately 30%
from the pipe inner wall; unless natural and wake frequency
calculations dictate shorter probe length or compliance or regulatory
applications require specific probe lengths.
7.1.10 Natural frequency and wake frequency calculations shall be performed
on all probes to determine maximum allowable length. Calculations
shall be performed per ASME PTC 19.3-2010.
Page 11 of 45
Document Responsibility: Instrumentation Standards Committee
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Next Planned Update: 15 September 2019
SAES-J-510
Process Analyzer Systems
7.1.11 Sample probes shall be all welded and designed in accordance with the
process pipe specifications and shall have the mechanical strength to
avoid failure under normal or abnormal flow conditions.
7.1.12 All sample probe data shall be included in the analyzer specification
sheet and probe drawings maintained in the appropriate database.
7.1.13 The sample point shall be located at least 3 pipe diameters downstream
from any flow disturbance or 90 degree bends. Applications or
processes that involve mixing stations; special consideration shall be
taken to ensure the sample is representative.
7.1.14 Sample taps/fast loops may be installed across plant equipment or
process pumps with relatively constant differential pressure.
7.1.15 Fast loops shall be designed based on 50% of the available differential
pressure between sample point pressure and sample return pressure.
7.1.16 Sample tap and fast loop locations that are not permitted:




Locations where there is a possibility of sample contamination.
Locations where multi-phase sample may present.
Locations where the flow is stagnant (dead legs).
Across a control valve or an orifice plate.
7.1.17 Installation of sample tap at the bottom of process pipe line shall be
avoided. Low point bleed shall not be used for sample tap.
7.1.18 For mixing reaction process applications; sample tap shall be located at
the point where the chemical reaction is completed.
7.1.19 Sample taps shall be accessible from grade or permanent platforms for
safe installation, maintenance, and isolation of process samples.
7.1.20 Sample taps shall be designed such that the bore size shall be the same
as that of nozzle size. If the nozzle penetrates the pipe wall, it shall be
set so that its end is in line with the pipe wall. This precaution reduces
the accumulation of deposits that tends to build up at sharp edges in the
sample path.
7.1.21 Sample tap/probe shall be fitted with a welded full bore isolation gate
valve. The assembly shall be hydrostatically tested and certified to
three times the operating pressure.
7.1.22 Sample probe shall be designed to minimize lag time. Probe sizing
Page 12 of 45
Document Responsibility: Instrumentation Standards Committee
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Next Planned Update: 15 September 2019
SAES-J-510
Process Analyzer Systems
shall consider sample lag time on the overall response, viscosity of the
process sample, and particle size of the contaminants in the process
sample.
7.1.23 Sufficient clearance and space shall be provided for maintenance of the
sample probes.
7.1.24 Sample probes shall be marked to indicate the direction of flow with
respect to the process flow.
7.1.25 Sample probes for special applications such as continuous emission
monitoring system (CEMS) and sulfur recovery plant analyzer
applications shall be designed in consultation with analyzer
manufacturer as a complete package.
7.1.26 Sample lines, sample taps and sample return valves shall be clearly
identified with the service and shall be tagged.
7.2
Sample Pre-Conditioning
7.2.1
Samples taken from the process may require pre-conditioning such as
cooling, heating, vaporizing, pre-filtering, pressure reduction or
pressure increase to meet the analyzer sample inlet condition
requirements.
7.2.2
Depending on the application, the pre-conditioning system components
shall be mounted on a 316 SS panel or enclosed in a 316 SS box, with
all components accessible for maintenance.
7.2.3
The pre-conditioning system shall be installed at or as close as possible
to the sample point.
7.2.4
All components in the pre-conditioning system shall be rated for the
relevant process conditions.
7.2.5
Pressure reduction of gas or vapor samples shall be done in the sample
pre-conditioning unit.
7.2.6
For vapor applications, a heated vaporizing pressure reducing regulator
shall be required if condensation is expected upon pressure reduction.
The vaporizer shall be heated above the maximum temperature at which
the sample exists in vapor phase to maintain sample dew point
temperature.
7.2.7
An electrically heated vaporizing pressure reducing regulators shall be
used if the liquid sample has to be vaporized for analysis.
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Document Responsibility: Instrumentation Standards Committee
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SAES-J-510
Process Analyzer Systems
7.2.8
The sample line downstream of the pressure reducing regulator shall be
electrically heat traced to maintain sample dew point.
7.2.9
A pressure gauge shall be installed directly downstream of the pressure
regulator or pressure reducer. A proportional relief valve shall be
installed at sample conditioning cabinet location.
7.2.10 The length of the sample line diameter from the sample probe to the
sample pre-conditioning system shall be kept as minimum to reduce
sample lag time.
7.2.11 For cryogenic services, the pre-conditioning cabinet shall be kept at a
constant elevated temperature.
7.2.12 Pumps shall be avoided unless absolutely necessary. Unless otherwise
specified, a pump shall be used only in the following situation:

If the pressure at the sample point is too low or if the liquid sample
may flash in the sample system.

If an analyzer such as a physical properties analyzer requires liquid
phase sampling and system pressure does not meet manufacture
specification requirements.
7.2.13 Pump selection shall be based on the flow and pressure requirement of
the analyzer and sample conditioning system.
7.3
Sample Lines
7.3.1
Length of sample lines shall be kept to a minimum and shall not exceed
100 m (328 ft).
7.3.2
Unless otherwise specified, overall sample lag time (from the sample
probe to the analyzer inlet port) shall not exceed 90 seconds.
7.3.3
Pressure drop, bubblepoint, phase diagram, and lagtime calculations
shall be performed on all liquid sample transport systems.
7.3.4
Dewpoint, phase diagram, and lagtime calculations shall be performed
on all vapor sample transport systems.
7.3.5
Lagtime and pressure drop calculations shall be used to determine
minimum sample transport tube diameter.
7.3.6
Two phase flow in the sample transport lines is not allowed.
7.3.7
For H2S, mercury, and moisture applications; sample transport tube
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Document Responsibility: Instrumentation Standards Committee
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Next Planned Update: 15 September 2019
SAES-J-510
Process Analyzer Systems
metallurgies (e.g., electro-polished/chemically passivated) for trace
level measurements (ppb or ppm) shall be selected to prevent chemical
reaction, adsorption and/or subsequent desorption effects between the
process sample and the sample line transport tube.
7.3.8
Liquid or vapor phase samples shall be transported to the analyzer
sample conditioning system using a continuous pre-insulated tube
bundle.
7.3.9
Continuous pre-insulated/pre-traced tube bundles shall be used for
applications that require heat tracing or cooling of process samples.
7.3.10 Pre-insulated electrical heat trace bundle shall be used for all process
sample transport lines that require heat tracing to prevent condensation
or require sample temperatures above its dewpoint. If the application
requires steam tracing the same requirement applies.
7.3.11 Field fabricated heat trace bundles are not allowed.
7.3.12 Electronic heat trace controllers shall be used to monitor electric traced
tube bundles. Controllers shall provide ground fault protection, current
protection, and shall alarm on high or low temperature conditions.
7.3.13 Electrical heat tracing components shall meet the area classification of
the area in which it is installed.
7.3.14 Pre-insulated steam trace tube bundle may be used for special
applications that require high heat loads or when technically required by
the analyzer manufacture.
7.3.15 Steam trace stainless steel tubes within the pre-insulated tube bundles
shall have a minimum of ⅜ inch diameter. ¼ inch stainless steel or
copper steam tracing tubes are not allowed.
7.3.16 Both ends of the pre-insulated sample bundle shall be sealed to prevent
moisture intrusion. Bundle ends located in the field or sample points
shall be sealed with heat shrink boots to provide weather proofing.
Bundle ends located inside the sample conditioning enclosures shall be
sealed with a black silicone sealant type.
7.3.17 Steam trace systems shall be equipped with a steam trap.
7.3.18 Sample dewpoint temperatures shall be at least 10 degrees higher than
the highest possible dew point of the sample and shall be controlled
within ±3 degrees of the required set point.
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Document Responsibility: Instrumentation Standards Committee
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SAES-J-510
Process Analyzer Systems
7.3.19 All sample transport lines (supply and return lines) shall be continuous
(without splices) from the sample tap / return point in a pre-insulated
tube bundle. Line splicing shall be avoided.
7.3.20 Pre-Insulated tube bundles shall use polyurethane jackets. Polyvinyl
chloride (PVC) jacket material shall not be used.
7.3.21 All sample transport lines and tube bundles shall be installed in
appropriate tray.
7.3.22 Pre-insulated sample bundles shall be installed and properly spaced in
tray according to manufacture specifications.
7.3.23 Pre-Insulated sample bundles shall be fastened to trays using vinyl
coated stainless steel straps. Use of nylon cable ties and non-coated
straps is not allowed. Bundles shall be fastened to the tray every
1 m (3.3 ft).
7.3.24 Sample transport lines and sample bundles shall be installed and sloped
for self-draining and with minimum low points to avoid liquid traps.
7.3.25 Single sample transport line systems shall be considered if suitable
return point in the process is not available for simple analyzers.
(i.e., pH, conductivity, and other water treatments analyzers).
7.3.26 If viscosity of the sample is more than 10 poise (1 Pa.s) at 30C (86°F),
the size of the transport line shall be 1.0 inch minimum to avoid
clogging. Highly viscous samples such as bitumen and asphalt typically
require 2.0 inch sample lines.
7.3.27 Non-heated sample transport lines (supply and return) shall have a
lockable shut-off isolation valves external to the sample condition
system. Applications that are temperature sensitive or require heat
tracing to maintain samples above its dewpoint shall have the shut-off
isolation valves located inside the sample conditioning system enclosure
to avoid cold spots.
7.4
Sample Conditioning Systems
7.4.1
The sample conditioning systems shall be designed and manufactured to
supply the analyzer with a continuous/representative and measurable
sample. It shall be designed in such a way that none of the process
sample analytical properties are changed between sample extraction
point and analyzer inlet and shall have no diurnal effect.
7.4.2
Sample conditioning systems designed by analyzer manufacturer shall
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Document Responsibility: Instrumentation Standards Committee
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meet or exceed the requirements of this standard. Analyzer System
Integrator shall take full responsibility for the performance of the
complete analyzer system.
7.4.3
Sample conditioning systems shall be built for the application for which
it is intended. Sample systems shall contain all the necessary metering
and filtering devices needed for conditioning of a representative sample.
7.4.4
Sample conditioning system enclosures shall only be used for housing
sample system components. Process analyzers and electronic sample
chillers are not allowed to be installed in sample system enclosures.
7.4.5
All sample system components and elastomers shall be rated and
compatible for the process conditions. All wetted parts shall be 316L
SS minimum for general applications.
7.4.6
All components shall be installed on a 316 SS mounting plate and
enclosed in a 316 SS enclosure.
Exception:
Simple analyzers that are designed for direct field installation; such
analyzers and their measurement cells/probes shall be installed on a 316
stainless steel mounting plate and mounted on a prefabricated instrument
pipe stanchion per Section 7.5.
7.4.7
Painted carbon steel or galvanized steel mounting plates and enclosures
are not permitted.
7.4.8
The sample conditioning systems and fast loop systems shall be
mounted on the outside walls of the analyzer shelter or analyzer cabinet
in a back-to-back configuration with the associated analyzer.
Exceptions:
The only scenario where a sample conditioning systems is allowed inside
the shelter or analyzer cabinet is when the analyzer is manufactured with
built-in sample conditioning hardware. The analyzer must be certified as
a complete (analyzer and sample conditioning) system and cannot be
separated without voiding its certification.
Examples of such analyzers with integrated sample conditioning systems
are SRU tail gas analyzers, physical properties analyzers, FTNIR
analyzers, etc.
7.4.9
All components shall be attached to the mounting plate in a manner that
they can be maintained, serviced, or removed from the front side of the
panel.
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7.4.10 Sample system enclosures shall meet requirements of NEMA 4X or
IP 66 to prevent dust/water ingress and corrosion. A caution warning
plate shall be provided on the front door, if the box is heated.
7.4.11 Samples shall be transported to the analyzer sample conditioning
cabinet using pre-insulated tubing through a fast loop system and shall
be filtered with a self-cleaning filter technology. Sample slip streams
shall be conditioned to meet analyzer vendor specification requirements.
7.4.12 All wet components installed in sour services applications shall comply
with requirements defined in Section 16.
7.4.13 Exterior mounted sample conditioning systems containing toxic gas
10 ppm or above shall be continuously vented with instrument air.
Effluent air from these systems shall be vented through an independent
cabinet bottom vent tube and monitored by a toxic gas detector mounted
next to the cabinet. The continuous vented air shall be metered with an
adjustable flowmeter and air flow shall be kept to a minimum (cc/min)
to allow heat retention within heated sample conditioning enclosure.
The toxic gas monitor shall alarm locally at the shelter and shall be
integrated into the plant gas detection system in accordance with
SAES-J-505.
7.4.14 Materials of construction shall be chosen to prevent chemical reaction,
adsorption and/or subsequent desorption effects between the process
sample and sample conditioning system.
7.4.15 Sample system enclosures shall be constructed of 316 stainless steel.
Galvanized steel is not allowed.
7.4.16 In corrosive applications wherever 316L stainless steel is not a suitable
material; preference shall be given to materials such as Monel,
Hastelloy or Incoloy.
7.4.17 Heated sample system enclosures shall be insulated for personnel
protection and heat loss prevention.
7.4.18 Top entry sample system cabinet penetrations are not allowed.
7.4.19 Sample tubing, sample bundles, drain lines shall be installed and bent in
a manner that they self-drain in a downward direction. Liquid traps
shall be avoided.
7.4.20 Sample conditioning system enclosures shall be closed and sealed with
a with 316 SS latch mechanisms.
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7.4.21 All incoming and outgoing connections shall be permanently tagged or
labeled.
7.4.22 All pressure, temperature, and flow components shall be provided with
tags or labels showing the respective settings.
7.4.23 All identification tags and name plates shall be engraved 316 SS and
shall be attached to the equipment securely with stainless steel or Monel
fasteners.
7.4.24 The maximum height of sample conditioning system shall not exceed
1.8 m (6.0 ft) from grade.
7.4.25 Vapor and liquid sample systems shall be provided with hardware for
introducing a calibration sample from outside the analyzer shelter or
analyzer cabinet.
7.4.26 Liquid samples shall be returned to the process. If liquid samples
cannot be returned directly to the process; then a liquid recovery system
shall be used to collect liquid process samples. The recovery system
shall have a collecting receiver with level-control, pump, and alarms.
An overflow drain or feature shall be provided in case the pump or
motor fails.
7.4.27 An adjustable proportional relief valve shall be installed downstream of
the pressure reducing regulator in the sample conditioning cabinet.
Based on the process pressure, the relief valve setting shall be 10% less
than the pressure rating of the lowest rated device within the sample
system. The relieved gas shall be vented to the flare line or sample
recovery system.
7.4.28 If the process sample inlet temperature to the analyzer is required to be
within specific limits, cooling or heating as appropriate shall be
provided within the sample conditioning system. Fresh water from the
main cooling systems shall be used. Sea water shall not be used as
cooling medium.
7.4.29 If the cooling water temperature is too high or not suitable, cooling by
means of a refrigeration chiller shall be considered. The refrigerated
chiller shall have an electric motor with single phase power supply.
7.4.30 Tubing shall be installed and arranged so that the removal of one
component does not require the dismantling of other parts.
7.4.31 Sample conditioning systems shall have facilities for flushing, venting
and/or draining with vent and/or drain valve(s). The vent/drain outlets
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shall be connected to a vent or drain system.
7.4.32 Dead volumes in the sample conditioning systems shall be kept to
minimum.
7.4.33 Armored flow meters shall be used in all hydrocarbon services.
7.4.34 Glass components shall only be used for N2, O2, or instrument air
service.
7.4.35 Glass components shall be rated for 2.0 times the maximum operating
pressure of the related system.
7.4.36 Instrument air lines and pneumatic signal lines shall be 316 stainless
steel tubing with compression fittings unless otherwise specified.
7.4.37 Pressure gauges for sample fluids shall have 2 in dial and provided with
a ¼ inch NPTM threaded connection. Pressure gauges shall be
positioned in the sampling system to avoid dead legs.
7.4.38 Pressure gauges shall be provided both upstream and downstream of
primary filters.
7.4.39 Unless otherwise specified, electrical heaters shall be used for heating
the sample conditioning enclosures.
7.4.40 A liquid recovery system shall be provided if process liquid sample
and/or byproducts cannot be returned to process due to non-availability
of low pressure return point. One common liquid recovery system can
be designed to serve one analyzer house or a cluster of analyzers.
A suitable common return point must be identified for each recovery
system.
7.4.41 The instrument air and nitrogen supply lines shall be provided with all
metal construction filtered regulators complete with pressure gauge and
back flow protection. Nitrogen regulators shall be of the non-bleeding
type. Plastic construction is not permitted.
7.4.42 Solenoid valves shall be used only for switching instrument air and
nitrogen. Pneumatically operated valves in combination with a solenoid
valve shall be selected for all other process fluids. Pneumatic actuator
shall be provided with a direct coupled mechanical position indicator.
7.4.43 The insulation of sample conditioning system enclosures shall be in
compliance with SAES-N-001.
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7.4.44 Flow restrictors shall be installed on all lines entering the shelter or
analyzer cabinet that contain flammable, toxic, asphyxiants, or
hazardous materials that are directly connected to a high pressure
(above 50 PSIG) source.
Commentary Note:
NFPA 496, 9.3.1.1 requires that orifices or other flow limiting devices be
installed outside and close to the wall of the shelter on any potential
source of uncontrolled leakage.
Exception:
Process streams that are prone to plugging (e.g., sulfur plant tail gas
analysis) are exempt from the above requirement. Also, when the
sample conditioning system is supplied as a “factory assembled” field
proven package, the sampling system can be integrated inside the
analyzer enclosure without flow restriction.
7.4.45 Sample systems containing highly toxic or flammable components shall
include facilities for purging with an inert gas prior to maintenance of
the sample system hardware.
7.5
8
Field Mounted Component Panels and Supports Stands
7.5.1
Simple analyzers and measurement probes as defined in Section 4 shall
be mounted on a 316 SS panel and prefabricated pipe stand.
7.5.2
Analyzer transmitters, measurement cells, and probes shall be installed
on panels for easy maintenance or replacement.
7.5.3
Prefabricated pipe stands shall be 2-inch schedule 40 pipe with a welded
anchor plate base.
7.5.4
The top of the pipe stand shall be sealed to prevent sand or water entry.
7.5.5
Pipe stands shall be hot-dipped galvanized.
Tubes and Tube Fittings
8.1
All tube fitting connectors shall be dual ferrule compression type and supplied
by an approved supplier listed in SAES-J-002.
8.2
Unless otherwise specified, 316 stainless steel type tubing shall be used as a
minimum for all process wetted parts downstream of the process sample
isolation valve.
8.3
As a minimum, tubing shall be seamless type, annealed 316 stainless steel in
accordance with ASTM A269.
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Document Responsibility: Instrumentation Standards Committee
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Process Analyzer Systems
Tubing minimum wall thickness shall be supplied per the Table below.
Tube Outside Diameter
Wall Thickness
½ inch
0.049 inch
⅜ inch
0.035 inch
¼ inch
0.035 inch
⅛ inch
0.028 inch
8.4
Aluminum or plastic tubing shall not be used as instrument tubing external to an
analyzer.
8.5
Tubing shall be cut using tube cutters and shall be bent or formed using tube
benders.
8.6
Tube fitting connections shall be made up according to manufacture
specifications and shall be inspected for proper makeup using a gap gauge.
8.7
Tubing shall be installed in perforated tray and secured with stainless steel
clamps. Perforated tray shall be within 150 mm (6 in) of the tube connection
point. Tubing shall be secured in tray with stainless steel tubing clamps every
1 m (3.3 ft).
8.8
Instrument tubing shall be adequately supported and secured on tray or channel
using clamps designed for and of the appropriate size for the tubing.
8.9
Pipe threaded or NPT connections 6 mm (½ inch) or smaller connections shall
be pre-coated with Teflon tape. Anaerobic pipe thread sealant may only be used
on threaded or NPT connections above 6 mm (½ inch).
8.10
Piping shall be designed, fabricated, and tested accordance with SAES-W-011 in
addition to ASME B31.3.
8.11
Standard specification for seamless tubing shall be as specified in SAES-J-003.
8.12
Tubing and headers shall penetrate analyzer shelters and analyzer cabinets
through a recessed bulkhead metal plate using bulkhead fittings. Holes drilled
through wall panels is not allowed.
8.13
Pre-insulated sample bundles shall penetrate shelter or cabinet through a
recessed bulkhead metal plate using a heat shrink entry seal assembly.
8.14
Tube unions in tray shall be installed with offset.
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SAES-J-510
Process Analyzer Systems
8.15
Tube fittings in hydrocarbon and toxic service and vent lines shall be kept to a
minimum to minimize leak sources.
8.16
Tube runs shall be installed in such a manner that it will not interfere with
maintenance activities or obstruct space allocated for future analyzer
installations.
8.17
All tubing and associated valves inside the shelter used for sampling, utilities
(carrier gas, air, water, etc.) and venting shall be furnished and installed with, and
terminated at, bulkhead fittings on the shelter bulkhead plates. Each bulkhead
fitting shall be tagged. Stainless steel, letter-stamped nameplates, secured by
stainless steel screws to the bulkhead plate, shall be used.
Sample Recovery Systems
9.1
Process samples and/or analysis byproducts, liquids or gases shall not be
discharged to atmosphere and shall be returned to process streams or flare where
possible.
9.2
Sample recovery systems as defined in Section 7.4.40; if required shall be custom
built for the intended service by the Analyzer System Integrator to meet the specific
needs of the analyzer systems.
9.3
Sample recovery systems shall have a suitable collection system consisting of a
level-control vessel or vessels with alarms and pump suitable for liquid samples.
9.4
A recovery system overflow drain shall be connected to a suitable drain system in
the event that a pump or motor failure occurs.
9.5
Sample recovery system liquid vessels shall be pressure tested and certified for the
intended service by a Third Party company. Self-certification is not allowed.
9.6
Sample recovery system vessels and piping shall meet the plants process pipe
pecification requirements.
9.7
Process samples and/or analysis byproducts, both liquids and gases shall not be
discharged to atmosphere and shall be returned to process streams or flare where
possible.
9.8
Process gas samples shall be vented to the flare system. Gases or vapors which are
returned to a flare system shall be routed to a header and shall have a check valve
installed to avoid backflow.
9.9
Aqueous fluids from analyzers using reagents or titration chemicals shall be
discharged into a plant containment system.
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SAES-J-510
Process Analyzer Systems
3-Sided Shelter
10.1
Sunshade General Requirements
10.1.1 3-sided shelters shall be naturally ventilated.
10.1.2 The pre-engineered shelter shall be shipped with the analyzer and all
ancillary equipment installed and tested before shipment.
10.1.3 Process analyzers placed under an outdoor 3-sided shelter shall meet the
environmental conditions listed in SAES-J-003.
10.1.4 Analyzers designed and certified as field mountable analyzers;
(e.g., field mounted gas chromatograph, BS&W analyzer, etc.) which
dissipate heat or require direct sunlight protection to prevent possible
electronic overheating may be installed under a 3-sided shelter.
10.1.5 Semi-Complex and Complex analyzer as defined in Section 4 shall not
be installed under 3-sided shelters.
10.2
Sunshade Structural Design
10.2.1 Pre-fabricated shelter shall be built in accordance with 12-SAMSS-014,
Pre-Engineered Metal Buildings for minimum design loads and design
procedures.
10.2.2 In addition to the basic construction requirements defined in
12-SAMSS-014 above, the sunshade shall incorporate the following
features:
10.2.2.1 Shelter walls shall be designed and installed to allow natural
air draft ventilation. A 150 mm (6 in) opening at the top of
the three walls is required with a 457 mm (18 in) open air
bottom is required.
10.2.2.2 The side walls shall extend 1 m (3.3 ft) beyond the front edge
of the analyzer enclosure.
10.2.2.3 The roof panel edges shall extend beyond the outer walls and
front side (all four sides) approx. 305 mm (12 in).
10.2.2.4 The shelter shall be sized to allow adequate work space
around the analyzer enclosure and sample conditioning
system. A minimum of 0.6 m (24 in) spacing shall be
available on either side of the analyzer enclosure (side wall to
analyzer distance) for maintenance activities.
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10.2.2.5 Lifting eyebolts shall be located on roof and attached to all
four corners.
10.2.3.6 Sunshade designed with a roof and no side walls or back wall
is not be permitted.
10.3
Sunshade Equipment Installation
10.3.1 Analyzers and sample conditioning systems installed under the
sunshade shall be attached to the back wall on unistrut to allow airflow
and heat dissipation. Direct wall mounting of equipment is not allowed.
10.3.2 Analyzers mounted on side walls is not allowed.
10.3.3 Signal junction boxes, power panel, and other analyzer ancillary
equipment can be mounted under the sunshade on the side walls.
10.3.4 Carrier gas regulators, calibration gas regulators, and bottle gas racks
shall be installed on the outer wall surface.
10.4
Sunshade Field Installation
10.4.1 Shelters located at grade shall be mounted on a concrete slab.
The concrete slab shall extend 1 m (3.3 ft) beyond the outer walls and
front side of the shelter.
10.4.2 Shelters shall be anchored in the field per vendor design.
10.4.3 Shelters shall be installed with the open side facing North or South to
avoid direct sun light exposure on the analyzer from the East or West
directions.
10.5
Sunshade Lighting and Power Outlets
10.5.1 Lighting and power outlet shall be provided under 3-sided shelters.
10.5.2 Light fixtures and switches shall be certified for Class I, Zone 2,
Groups IIC, IIB, & IIA or as necessary depending on the materials
being handled within the area.
10.5.3 A power outlet for the connection of test equipment shall be provided.
Receptacles shall be suitable for operation in Class I, Zone 1,
Groups IIC, IIB, & IIA or as necessary depending on the materials
handled within the area.
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SAES-J-510
Process Analyzer Systems
Analyzer Cabinet Design
11.1
Cabinet General Requirements
11.1.1 Process analyzers placed inside analyzer cabinets shall meet the
minimum environmental temperature requirements listed in
SAES-J-003.
11.1.2 Cabinets shall be rainproof and dustproof and shall be designed to
withstand the environmental conditions specified in SAES-A-112
Meteorological and Seismic Design Criteria.
11.1.3 Pre-engineered analyzer cabinets shall be shipped with the analyzer
installed and all systems (air conditioner, auxiliary ventilation fan,
purge systems, lighting, and power supply systems) in place and tested
before shipment.
11.1.4 Analyzer cabinets shall only be used in analyzer applications that
require installation on elevated platforms that have limited space, are in
remote plant locations, or are in toxic service.
11.1.5 Complex analyzers as defined in Section 4 shall not be installed in
analyzer cabinets. Complex analyzers shall only be installed in analyzer
shelters.
11.1.6 Maintenance and repairs shall be performed on analyzer equipment
while standing outside of the cabinet with the doors open.
Analyzer cabinets shall not be designed for personnel entry.
11.1.7 Cabinet interior shall be large enough to allow adequate space for
maintenance activities.
11.1.8 Analyzer cabinets shall provide environmental protection and
climate control for only one single process analyzer and gas detectors.
Multiple process analyzer installation in cabinets is not allowed.
11.1.9 Only the process analyzer and ancillary equipment associated with
analyzer operation (e.g., HMI, control unit, etc.) shall be permitted
inside the cabinet.
11.1.10 Wall mounted ventilator and louvers shall be made of corrosion
resistant material.
11.1.11 The cabinet shall be insulated per 12-SAMSS-014.
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Document Responsibility: Instrumentation Standards Committee
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11.2
SAES-J-510
Process Analyzer Systems
Cabinet Structural Design
11.2.1 Pre-fabricated cabinets shall be built in accordance with 12-SAMSS-014,
Pre-Engineered Metal Buildings for minimum design loads and design
procedures.
11.2.2 Cabinet exterior dimensions shall not exceed 2 m (L) x 1.2 m (W) x
2.5 m (H) and shall have two front doors.
11.2.3 Analyzer cabinets shall be designed for a single analyzer installation
with no extra analyzer slot for future expansion.
11.2.4 Cabinets external wall space shall be used to install air conditioner and
all exterior ancillary equipment.
11.2.5 In addition to the basic construction requirements defined in
12-SAMSS-014 above, the cabinet shall incorporate the following
features:
11.2.5.1 Doors shall open outwards and shall have steel frames.
Doors shall be sized to permit the removal and installation of
analyzer equipment.
11.2.5.2 Cabinet doors shall be equipped with locks and door stops.
11.2.5.3 One door shall be equipped with internal upper and lower
slide bar latches and the main door shall have an external key
lock/door handle mechanism.
11.2.5.4 Detachable sunshade covers 1 m (3.3 ft) long shall be
provided on all four sides of the cabinet.
11.2.5.5 Cabinets shall have an integrated seal welded floor to prevent
ingress of hydrocarbons. Use of silicone or other sealants is
not allowed.
11.3
Cabinet Equipment Installation
11.3.1 Process analyzers in the cabinet systems shall be installed in such a
manner that will allow airflow around the analyzer for maximum heat
dissipation. Direct wall mounting of equipment with no air gap
between the analyzer and wall is not allowed.
11.3.2 Analyzer equipment or ancillary equipment mounted on cabinet internal
side walls is not allowed.
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11.3.3 Analyzers mounted in cabinets (e.g., process analyzer, gas detectors, etc.)
shall be as close as possible to the front door plane. The maximum
allowable distance between the front plane of the process analyzer and the
back side of the closed front doors shall not exceed 150 mm (6 in).
All analyzers and gas detectors shall maintainable or repairable within
arms’ reach; while standing on the outside of the cabinet.
11.3.4 The top elevation of the process analyzer shall not exceed 2 m (6 ft) in
height while standing in front of the cabinet.
11.3.5 Electrical power panels, signal junction boxes, utility headers,
calibrations cylinders, gas regulators, instrument air filters, air
conditioner, etc., shall be mounted on the exterior walls of the cabinet.
11.3.6 Bulkhead plates 300 mm x 300 mm (12 in x 12 in) shall be placed at the
top and bottom of the walls.
11.3.7 Tubing, sample lines, calibration gas, utility headers, etc., shall be
penetrate cabinet walls through recessed bulkhead plates.
11.3.8 Flare header and atmospheric vent header piping shall be located
outside the cabinet and installed below the sample conditioning system
to allow condensables to drain downward. Headers shall have a low
point drain valve. Cabinet flare headers and atmospheric vent headers
installed above the sample conditioning systems is not allowed.
11.4
Cabinet Installation
11.4.1 A minimum walking space of 1.5 m (5 ft) shall be provided around all
exterior cabinet sides.
Commentary Note:
The intent is to provide adequate working space around analyzer cabinets
to facilitate routine maintenance (the movement of equipment around the
cabinet, calibration cylinders, and working space for maintenance
personnel) and to provide a clear path in the event of an emergency.
11.4.2 Cabinet applications that require to be as close as possible to the sample
point (e.g., SRU Air Demand analyzer) due to low sample supply and
return pressure shall be placed at an elevation higher than the sample
point to allow the sample system to self-draining back to the sampling
point.
11.4.3 Analyzer cabinets designed to handle flammable or toxic samples shall
be installed in Class 1 Zone 2 areas.
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Process Analyzer Systems
11.4.4 Analyzer cabinets shall not be installed in Class 1, Zone 0 or Zone 1
areas.
11.4.5 Analyzer cabinets designed to handle non-flammable or non-toxic
samples and are designed for general purpose use; such cabinets shall be
installed only in non-hazardous areas.
11.4.6 Cabinets located at grade shall be mounted on a elevated concrete slab.
The finished cabinet floor elevation shall be a minimum of 8 in above
grade.
11.4.7 The concrete slab shall extend 1.5 m (5 ft) minimum beyond the front
doors of the cabinet and the width of the slab shall be the same as the
cabinet width.
11.4.8 Cabinets installed on elevated platforms or metal grading shall be
installed at grading elevation. Grading underneath the cabinet shall be
designed to support the weight of the cabinet system.
11.4.9 Cabinets shall be anchored to concrete slab or metal grading structure
per vendor design.
11.5
Cabinet Ventilation and Air Conditioning Requirements
11.5.1 Cabinet installations shall be provided with a minimum of one air
conditioner. If the analyzer is deemed critical and is specified as such
or on-line analyzer availability requirements are mandated within the
Saudi Aramco instrument specification sheet; such installation shall
require two air conditioners.
11.5.2 Air conditioners shall be commercial grade and suitable for use in a
Class 1, Zone 2 locations for the gas groups and temperature class
appropriate to the analyzer application and hazardous area
classification.
11.5.3 Air conditioning system shall maintain 24°C (75°F) internal air
temperature (±5°F throughout the cabinet).
11.5.4 Analyzer cabinets are not designed for personnel entry; therefore,
cabinet pressurization is not required.
11.5.5 Vortex coolers and thermal electric coolers shall not be used for cooling
analyzer cabinet applications.
11.5.6 Air conditioner shall be window type unit.
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11.5.7 Window type air conditioning units shall be removable from the outside
mounting flange/bracket assembly for quick replacement or repair.
Removal of air conditioner unit from the inner side of the cabinet is not
allowed.
11.5.8 A temperature transmitter with local display shall be installed on the
exterior side wall of the analyzer cabinet. An RTD sensor shall be
installed internal to the cabinet.
11.5.9 Temperature transmitter shall alarm HIGH Internal Cabinet Temperature
in the control room when cabinet internal temperature reaches within
20% of the analyzer maximum allowable ambient temperature limit.
The transmitter shall alarm HIGH HIGH when the internal temperature
reaches 5% of the analyzer maximum ambient temperature limit as
defined by the analyzer equipment manufacturer specification.
11.5.10 Cabinets shall be provided with a wall mount auxiliary ventilation fan.
11.5.11 The auxiliary ventilation shall be powered from a non-ups power source.
11.5.12 The auxiliary ventilation fan shall be interlocked and energized to
provide fresh air ventilation into the cabinet upon detection of a HIGH
HIGH internal hydrocarbon or toxic gas or HIGH HIGH internal
cabinet temperature.
Exception:
Analyzer cabinets installed in non-classified areas; auxiliary ventilation
fans in such installations shall provide fresh air ventilation into the cabinet
upon detection of HIGH HIGH internal cabinet temperature.
11.5.13 The external wall mounted auxiliary ventilation fan shall be sized to
provide a minimum of 6 air changes per hour of fresh air.
11.5.14 The fresh air intake shall be provided with rain hood and bug screen.
11.5.15 Cabinet gas detection alarms and alarm management shall be provided
by the plant DCS per SAES-J-505.
11.5.16 The auxiliary ventilation fan shall have a local Hand/Automatic control
selector switch feature with pilot light. The pilot light shall be
illuminated and visible from the front of the cabinet upon fan activation.
11.5.17 The auxiliary ventilation fan shall provide fresh air into the analyzer
cabinet and out through a corrosion resistant barometric discharge louver.
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11.5.18 Cabinet barometric louvers shall be placed at elevations and locations
that maximizes the hydrocarbon dilution rate upon loss of hydrocarbon
containment.
11.5.19 The auxiliary ventilation fan shall have a direct-drive motor. Belt driven
fans are not allowed.
11.5.20 The auxiliary ventilation fan shall have a self-closing corrosion resistant
back-draft louver.
11.5.21 Auxiliary ventilation and air conditioning fans shall be spark resistant.
11.6
Cabinet Lighting and Power Outlets
11.6.1 Lighting shall be provided inside analyzer cabinets, over the exterior
door entrance underneath the front sunshade, and under the sunshade
cover above exterior sample conditioning system.
11.6.2 Light fixtures and switches associated with the analyzer cabinet shall be
certified for Class I, Zone 2, Groups IIC, IIB, & IIA or as necessary
depending on the materials being handled within the area.
11.6.3 A power outlet for the connection of test equipment shall be provided
on the external wall of the cabinet. The receptacle shall be suitable for
operation in Class I, Zone 1, Groups IIC, IIB, & IIA or as necessary
depending on the materials handled within the area.
12
Walk-In Analyzer Shelters
12.1
Shelter General Requirements
12.1.1 Pre-engineered shelters shall be shipped with analyzers installed and all
systems (air conditioners, ventilators, purge systems, lighting and power
supply systems) in place and tested before shipment.
12.1.2 Shelters shall be rainproof and dustproof and shall be designed to
withstand the environmental conditions specified in SAES-A-112
Meteorological and Seismic Design Criteria.
12.1.3 Only analyzers and equipment associated with analyzer operation
(e.g., analyzer HMI’s, analyzer control panels, etc.) shall be permitted
inside the shelter. Furniture, tables, sinks, storage cabinets, etc., are not
allowed in shelters.
12.1.4 Shelter interior shall be large enough to allow adequate access and
space for maintenance and repair activities. Analyzers shall have a
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maximum 600 mm (24 in) of free space on each side or between
individual analyzers.
12.1.5 Where plant instrument air is not available (e.g., pipeline or remote
facilities), the instrument air supply system if required, shall be
provided with the analyzer system and shall either be installed in a
separate shelter room or external to the analyzer shelter.
12.1.6 Detachable sunshade covers 1.2 m (4 ft) long shall be attached on the
two longest sides of the shelter over the sample system cabinets.
12.1.7 Finished floor elevation shall be a minimum 8 in. above grade.
12.1.8 The shelter shall be insulated per 12-SAMSS-014.
12.1.9 Inert gas shall not be used for purging an analyzer shelter and shall only
be used for enclosure purging when instrument air is not suitable.
When inert gas is required to purge an enclosure within the analyzer
shelter, an oxygen detector shall be provided inside the shelter.
An alarm shall be initiated remotely at the DCS and a magenta colored
beacon shall be activated outside the analyzer shelter over every door
entrance and an internal and external audible horn shall activate when
the oxygen level drops below the safe occupational exposure limit.
Commentary Note:
Instrument air is preferred for enclosure purging as leakage of inert gases
used for purging or pressurizing of enclosures in an analyzer shelter can
deplete the room's oxygen content.
12.2
Shelter Structural Design
12.2.1 Pre-fabricated shelters shall be skid-mounted and shall be supplied
in accordance with Sections 5, 9, and 11 of 12-SAMSS-014,
Pre-Engineered Metal Buildings for minimum design loads and design
procedures.
12.2.2 Shelters shall be designed for multiple analyzer use and shall provide
one extra analyzer slot with additional sample system slot on the outside
wall of the shelter for future expansion.
Exception:
In cases where only one complex or semi complex analyzer needs to be
installed in a walk-in analyzer shelter and there is no foreseeable analyzer
expansion requirement; the shelter size may be sized for only one analyzer
installation with no extra analyzer slot. Minimum size shelter for such
application shall be 2.5 m x 2.5 m x 2.5 m with single door.
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12.2.3 In addition to the basic construction requirements defined in
12-SAMSS-014, the shelter shall incorporate the following features:
12.2.3.1 Shelter doors shall open outwards, be self-closing, and shall
have steel frames. Doors shall be sized to permit the removal
and installation of equipment.
12.2.3.2 All shelters greater than 10 m² in size, shall have a minimum
of two door exits, located at opposite ends of the shelter.
12.2.3.3 An inspection window shall be installed in each shelter door.
Glass shall be laminated or tempered safety glass meeting the
requirements of ANSI Z 97.1. The window shall not exceed
0.065 m2 (100 in2) in area.
12.2.3.4 All doors shall be equipped with quick-opening bars (panic
bars) on the inside, which shall override exterior locks.
12.2.3.5 Roof or wall mounted ventilators and louvers shall be made
of corrosion-resistant material.
12.2.3.6 Lifting holes in the skid shall be provided to permit a safe
four-point lift to a minimum height of 6 m using spreader
bars and a single hook.
12.2.3.7 Prefabricated shelters shall be provided with a slip resistant
integrated floor.
12.2.3.8 The integrated floor shall be seal welded to prevent the
ingress hydrocarbons. Use of silicone or other sealants is not
allowed.
12.3
Shelter Equipment Installation
12.3.1 Analyzers shall be installed in such a manner that will allow airflow
around the devices for heat dissipation. Direct wall mounting of
equipment is not allowed.
12.3.2 Electrical power panels, signal junction boxes, and instrument air filters
shall be mounted on the exterior walls of the shelter.
12.3.3 Bulkhead plates 300 mm x 300 mm (12 in x 12 in) shall be placed at the
top and bottom of the walls.
12.3.4 Tubing, sample lines, calibration gas, utility headers, etc., shall
penetrate shelter walls through a recessed bulkhead plates.
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12.3.5 Shelter flare headers and atmospheric vent headers installed above the
sample conditioning cabinets is not allowed. Flare headers, atmospheric
vent headers, nitrogen headers, and steam headers shall be located
outside the shelter and installed below the sample conditioning systems
elevation.
12.4
Shelter Installation
12.4.1 A minimum walking space of 3 m (10 ft) from the exterior shelter walls
shall be provided around all shelter sides.
Commentary Note:
The intent is to provide adequate working space around analyzer shelters
to facilitate routine maintenance (the movement of equipment in and out
of the shelter, storage of gas cylinders, and working space for
maintenance personnel) and to provide a clear path in the event of an
emergency. A minimum of 1 m distance from the analyzer shelter to
structural steel columns is acceptable provided free access to sample
conditioning systems and exit doors is available.
12.4.2 Analyzer shelters designed to handle flammable or toxic samples shall
be installed in Class 1 Zone 2 areas.
12.4.3 Analyzer shelters shall not be installed in Class 1 Zone 0 or Zone 1
areas.
12.4.4 Analyzer shelters designed to handle non-flammable or non-toxic
samples and are designed for general purpose use; such shelters shall be
located only in non-classified areas.
12.5
Analyzer Shelter Ventilation and Air Conditioning Requirements
12.5.1 Shelters which are located in Class I, Zone 2 areas; the HVAC systems
shall be designed to prevent the accumulation of flammable vapors or
toxic gases.
12.5.2 Pressurization and HVAC systems for analyzer shelters shall comply
with NFPA 496, Chapters 7 and 9.
Commentary Note:
Analyzer shelters are force ventilated to prevent hazardous gas or vapor
from accumulating inside the shelter. The inside of an analyzer shelter
presents special safety problems because hazardous vapor or gas is
being introduced into an enclosed structure. An unventilated shelter is
classified as a Class 1, Zone 1 area. It is normal practice in Saudi
Aramco to ventilate analyzer shelters to maintain a Class 1, Zone 2 area.
This is achieved by ensuring that the worst single contingency leak can
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be diluted to less than 25% of its LEL or occupational hazard threshold
limit value. This design philosophy is based on a single contingency
failure.
12.5.3 Analyzer shelter HVAC’s shall be provided with a pressurization
system that continuously ventilates the shelter with a flow of clean fresh
air in accordance with NFPA 496.
12.5.4 HVAC’s shall be commercial grade units designed for use in hazardous
areas.
12.5.5 HVAC systems shall maintain 24°C (75°F) indoor air temperature
(±5°F throughout the shelter).
12.5.6 HVAC systems shall be fitted with a humidistat to control humidity
levels within the shelter.
12.5.7 HVAC requirements for shelters shall be met by using two separate
HVAC/air handler units (primary and standby) located at opposite ends
of the shelter and an independent roof mounted auxiliary ventilation fan
as backup. The cooling capacity of each HVAC shall be adequate to
handle all cooling loads of the shelter.
Commentary Note:
Dual redundant HVAC/air handler units provide a completely independent
backup to facilitate continuous operation of process analyzers when
HVAC failure occurs or when maintenance is required. Roof mounting is
required for the back-up auxiliary ventilation fan to allow a built-in escape
path for any accumulation of lighter-than-air flammable gas
concentrations during an extended ventilation failure and to provide a
means to purge the shelter prior to starting the HVAC units.
12.5.8 Each HVAC unit shall be powered from different power sources to
ensure redundancy.
12.5.9 Each HVAC shall have an individual switching device (power disconnect
switch) intended to be used for electrical isolation. This switching device
shall be equipped with a pad lockable lock-off device which will
mechanically prevent the connection of the primary power to the HVAC
when the padlock is installed and shall be located near each HVAC unit.
Primary power for each HVAC unit shall be supplied from the substation
breaker.
12.5.10 Each HVAC/air handler unit shall be capable of providing a minimum
of 6 air changes per hour of fresh ventilation to dilute any release of
flammable gas or vapor to a concentration less than 25% of the lower
flammable limit.
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12.5.11 One HVAC shall operate continuously with the other as standby.
Auto changeover switches shall be provided between the operating
and standby unit. These switches shall be capable of providing
changeover and equal wear and tear between operating and standby
unit. Standby unit shall auto-start upon loss of air flow from the
primary unit.
12.5.12 Heat gain from introducing outside air into the shelter shall be included
in the HVAC load calculation.
12.5.13 Ventilation fresh air make up shall be taken from a non-hazardous area.
If this is not available, Class 1 Zone 2 air may be used if the equipment
installed in the analyzer shelter is suitable for Zone 2 or worse location.
12.5.14 Corrosion resistant barometric weighted louvers shall be used to
maintain the internal pressure at 25 Pa (0.1 inch W.C.).
12.5.15 Shelter barometric louvers shall be strategically placed at elevations and
locations that maximize the hydrocarbon dilution rate upon loss of
hydrocarbon containment.
12.5.16 Fresh air stack inlet shall include a rain shield and bug screen.
12.5.17 Dust filters shall be located in the fresh air ventilation air intake duct
and HVAC air return. Filters shall be installed at an easily accessible
location for cleaning or replacement.
12.5.18 Air flow shall ensure adequate cross ventilation and air discharge
louvers shall be located at the top and bottom of the room to prevent the
accumulation of vapor pockets.
Commentary Note:
Air flow shall capture flammable vapors as close as possible to the
source, taking into account that vapors such as heavier-than-air
hydrocarbon vapors shall be removed at floor level and lighter-than-air
gases such as hydrogen and methane shall be removed at the ceiling.
12.5.19 The analyzer shelter shall be provided with an auxiliary ventilation
fan/motor. The auxiliary ventilation fan shall provide a minimum of
6 fresh air changes in the event of an internal flammable/toxic gas leak
or oxygen deficiency event.
12.5.20 The auxiliary ventilation shall be powered from a non-UPS power
source.
12.5.21 The auxiliary ventilation fan fresh air stack intake shall be located
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3 m (10 ft) above the shelter roof. The fresh air stack shall have a
3-point support system.
12.5.22 The fresh air intake shall be provided with rain hood and bug screen.
12.5.23 The auxiliary ventilation fan shall interlock and energize upon any
HIGH HIGH alarm associated with flammable gas, toxic gas, or LOW
oxygen deficiency.
12.5.24 The auxiliary ventilation fan shall have a direct-drive motor. Belt driven
fans are not allowed.
12.5.25 The auxiliary ventilation fan shall have a self-closing corrosion resistant
back-draft louver.
12.5.26 Roof mounted ventilation fan/blower shall be of a non-sparking
construction and the drive motor shall be suitable for use in a Class 1,
Zone 1 location for the gas groups appropriate to the analyzer
applications. The roof mounted ventilation fan shall be capable of
meeting dilution requirement of Section 7.3 [NFPA 496, 9.2.1(2)] and
provide the pressurization via weighted louvers of Section 7.5
(NFPA 496, 7.4.1) with both of the HVAC systems out of service.
Exception:
Ventilation fans or purge blower motors that are located external to the air
handling ductwork shall be suitable for the hazardous area where they
are mounted.
Commentary Notes:
Air conditioners must be certified for the area in which they are installed.
However, individual electrical components (ventilation fan motors, etc.)
may be certified or the unit may be certified as a package.
When hydrogen is introduced within the shelter as carrier gas, the
ventilation fan motor does not have to be certified to gas group B or IIC
provided the hydrogen supply line has an orifice restrictor outside the
shelter.
12.5.27 Roof mounted auxiliary ventilation fan motor shall be equipped with a
manual starter or a contactor type starter mounted on the exterior of the
shelter. The auxiliary ventilation fan shall have a local manual /
automatic control selector switch with a red pilot light indicator.
The pilot lights shall be illuminated and visible at each exterior door
entrance upon fan activation.
Commentary Note:
The requirement for an exterior mounted manual starter for the roof
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mounted ventilation fan provides a way to purge the shelter of any
combustible vapors that may have accumulated during an extended
power outage prior to entering the shelter and starting the HVAC system.
12.5.28 Ventilation or HVAC air handling unit fans shall be fabricated with
spark resistant construction.
12.5.29 A flow switch shall be provided within the air duct of each HVAC air
handling unit to give a low-flow alarm in the control room (or other
constantly attended location) and to initiate a white beacon mounted
outside the analyzer shelter door upon low-flow condition (recommend
60% of design flow). The two flow switches shall be voted (2-out-of-2)
to alarm only upon loss of air flow through both the primary and the
standby HVAC systems. A time delay of up to 1 minute may be used to
prevent spurious alarms. Flow switches shall be certified for a Class 1,
Zone 1, Group IIC, IIB, & IIIA.
Upon loss of air flow through both the primary and the standby HVAC
systems, the roof-mounted auxiliary ventilation fan shall be
automatically started. Upon loss of all shelter ventilation (HVAC and
auxiliary fan), the roof mounted back-up fan shall be started first to
purge the shelter prior to restarting the HVAC system.
Commentary Note:
Because the interior of the shelter is classified as Class I, Zone 2, all the
equipment inside the shelter is suitable for use in a "limited release"
environment (under normal operating conditions). Two failures are
required to introduce a hazard inside the shelter (undetected pressurization
failure for sufficient time for an explosive mixture to accumulate and a fault
in the Class I, Zone 2 certified equipment). The design requirements are
based on NFPA 496, 9.3.8 (3) that offers an exception to automatic
shutdown upon loss of pressurization if the anticipated release is "limited"
and the analyzer room is classified as Class I, Zone 2.
12.6
Shelter Lighting and Power Outlets
12.6.1 Lighting shall be provided inside analyzer shelters, over each exterior
door entrance, and under the sunshade covers above exterior sample
conditioning systems per SAES-P-123 requirements.
12.6.2 Light fixtures and switches associated with the shelter shall be certified
for Class I, Zone 2, Groups IIC, IIB, & IIA or as necessary depending
on the materials being handled within the area.
12.6.3 A power outlet for the connection of test equipment shall be provided
inside the shelter. Receptacles shall be suitable for operation in Class I,
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Zone 1, Groups IIC, IIB, & IIA or as necessary depending on the
materials handled within the area.
13
Headers and Vents
13.1
Carrier gas, zero gas, steam, and instrument air purge headers shall be used
whenever two or more analyzers share common services. An isolation valve
shall be provided at each header take off point. All headers shall be provided
with a minimum of two spare un-valved capped connections.
13.2
Instrument air headers shall slope to a low point drain. A drain valve shall be
installed inside the shelter. The drain line shall be connected to a bulkhead
fitting.
13.3
A wall mounted compressed instrument air membrane air dryer designed for
analyzer shelters with built-in coalescing prefilter shall be installed on the
exterior wall of the shelter or analyzer cabinet; upstream of the outer bulkhead
plate fitting or analyzer systems.
13.4
The membrane air dryer/coalescing prefilter shall have an automatic drain
feature, self-regenerate, and must output -20°C or lower dewpoint or shall meet
the analyzer equipment manufacture specification requirements.
13.5
The membrane air dryer/coalescing prefilter shall be sized for output flow
capacity based on the analyzers worst case consumption rates located within the
shelter or analyzer cabinet.
13.6
The instrument air system shall have a built-in bypass system that allows air
dryer/coalescing filter maintenance or replacement.
13.7
Analyzer slip-stream gas sample flows shall be vented to the flare header or
back to the process line if liquid.
13.8
Analyzers requiring atmospheric reference vents (e.g., gas chromatographs)
shall be connected to an external atmospheric vent header.
13.9
Atmospheric reference vents and carrier gas/column vents shall be led to a freely
ventilated point more than 3 m above the shelter and more than 7.5 m from any
ventilation air intake or ignition source. The area around the vent discharges
should be classified Class 1, Zone 0 per SAES-B-068 Electrical Area
Classification.
13.10 Atmospheric reference vent headers and carrier gas vent headers shall be
provided with a low point drain with isolation valve and separate bulk head
connections.
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13.11 The functions and content of piping, tubing, and valves shall be clearly marked.
14
Calibration and Gas Cylinders Racks
14.1
Remote cylinder racks shall be used for storing carrier gases and calibration
blends. Racks shall be located near the analyzer shelter or analyzer cabinet.
14.2
Low volume liquid or low pressure calibration cylinders that require close
proximity to the sample conditioning system shall be located on the exterior wall
of the shelter next to the sample conditioning cabinet. All other calibration
cylinders shall be tubed up from a nearby cylinder rack to free up shelter wall
space.
14.3
Remote cylinder racks shall have a sun shade cover to reduce direct sun light
exposure. Sunshade roof shall provide 1 m (3.3 ft) of shade on each side of the
rack from the center line of the rack.
14.4
If calibration cylinders require a temperature controlled environment; such
system shall be provided by the Analyzer System Integrator.
14.5
Remote cylinder racks shall have approx. 30% additional space for spare
cylinder storage.
14.6
Carrier gas and hydrogen gas cylinder manifold systems shall be designed so
that the secondary or standby cylinder automatically supplies gas when the
primary bottle is empty.
14.7
Carrier gas and hydrogen gas cylinder manifolds systems shall be designed to
permit the removal of any cylinder without stopping the gas flow from the other
remaining cylinder(s) in the manifold.
14.8
The manifold's maximum allowable working pressure shall exceed the pressure
in the cylinders connected to it.
14.9
The vendor shall supply manifold piping or tubing, fittings, pressure gauges and
pressure reducing regulators for each cylinder (primary and secondary) position.
14.10 Each cylinder storage position shall have a safety chain or safety bar to hold the
cylinder in position.
14.11 Each GC shall have a dedicated carrier gas tubing header. Connecting multiple
GC(s) on the same carrier gas header is not permitted.
Commentary Note:
If a carrier gas leak develops and multiple GCs are installed on the header it
becomes difficult to determine which GC is the source of the leak.
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14.12 Cylinder gas manifolds shall incorporate discharge safety devices at the rack or
external to the shelter or analyzer cabinet.
14.13 Calibration gas and carrier gas cylinders containing flammable gas shall not be
closer than 7.5 m to pumps or other possible sources of ignition when possible.
15
Combustible Gas / Toxic Gas / Oxygen Detection
15.1
If a source of combustible or toxic gas is analyzed or present in the area,
combustible gas and/or toxic gas monitors shall be installed in each analyzer
shelter or analyzer cabinet in accordance with SAES-J-505.
15.2
Detectors shall be integrated into the plant wide gas detection system to provide
alarm indication and alarm management.
15.3
Detectors shall be installed with fail-safe alarms.
15.4
Combustible gas and toxic gas monitors shall comply with 34-SAMSS-514
requirements.
15.5
Upon detecting combustible or toxic gas, low oxygen concentration, or monitor
malfunction; the combustible gas, toxic gas, or oxygen deficiency monitors shall
actuate both an alarm in the manned control room (or other constantly attended
location) and local alarms. In addition, separate warning exterior light beacons
and audible horns mounted outside the shelter or analyzer cabinet doors shall be
provided.
15.6
Walk-In analyzer shelters shall be provided with a low decibel internal audible
horn in addition to the external beacon and horn requirements.
15.7
Beacon colors shall be as follows:

Blue beacon for high hydrogen sulfide


Red beacon for combustible gas
Magenta beacon for oxygen deficiency
15.6
Shelter auxiliary ventilation fan shall be interlock and energize upon any HIGH
HIGH alarm associated with internal combustible or toxic gas detection or low
oxygen deficiency detection. Shelter alarms and alarm management shall be
provided by the plant DCS.
15.7
The analyzer cabinet auxiliary ventilation fan shall be interlocked and energized
upon any HIGH HIGH alarm associated with internal combustible or toxic gas
detection or HIGH HIGH internal cabinet temperature. Gas detection alarms
and alarm management shall be provided by the plant DCS.
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Commentary Note:
Combustible and Toxic gas sensors should not be used to initiate automatic
power isolation or to isolate the pressurization fans or air handling units.
15.8
Analyzer sample conditioning system enclosures utilized in toxic service shall
be monitored by a toxic gas monitor and shall be integrated into the plant wide
gas detection system to provide alarm indication and alarm management.
15.9
Combustible gas monitors shall be mounted on the inside walls of the analyzer
shelter.
15.10 Analyzer shelters shall be provided with an oxygen deficiency monitor.
15.11 Beacons and audible alarms shall be located over each analyzer shelter door
entrance or above the analyzer cabinet and shall be clearly visible from all
directions.
15.12 Shelters and analyzer cabinets shall be provided with fail-safe hermetically
sealed interposing relays. Interposing relays shall de-energize to activate
beacons and audible alarms.
15.13 Outdoor audible alarms shall be audible both inside and outside the shelter with
shelter doors closed.
15.14 Detector locations shall depend upon the relative densities of the hazardous
substances being handled. It may be necessary to detect light gases near the roof
level and heavy gases and vapors near the floor level. At least one sensor for
every 14 m² of floor area shall be installed.
15.15 Detector logic system or control unit for alarm and alarm management shall be
per SAES-J-505 requirements.
15.16 Detector setpoints and calibration ranges shall be set per SAES-J-505
requirements.
16
Sour Service Applications
16.1
All analyzer sample probes, sample isolation valves, pipe fittings, welded pipe
connections, pressure reducing regulators, sample lines, etc., operating under
sour gas and oil environments service shall utilize materials, alloys, fabrication
techniques, and coatings as specified within NACE MR0175/ISO 15156.
16.2
Gas analyzers in sour service shall have their sample supply pressure reduced at
the sample point location to a pressure below 65 psia.
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Commentary Note:
This could potentially allow the use of standard commercial materials
downstream of the pressure reducing regulator depending on H2S concentration,
H2S partial pressure, gas properties, corrosiveness, and application temperature.
17
18
16.3
The gas pressure setting must be supported by calculations or support
documentation to ensure materials selected are suitable for the intended service.
If such system cannot be supported by calculations or support documentation;
then a conservative approach shall be taken with material selection downstream
of the sample point pressure reducing regulator; such materials shall be selected
per NACE recommendations.
16.4
Analyzer systems in sour service that require liquid phase sampling; such systems
shall be installed or located as close as possible to the sample supply tap.
16.5
If it is not possible to install the liquid phase analyzer system close to the sample
supply tap; then sample supply and return lines shall be extended to the analyzer
system using continuous welded pipe. Such piping installations shall be kept to
an absolute minimum distance and shall comply with NACE requirements.
16.6
Sample tubes, tube fittings, valves, and other sample system components used in
sour service shall comply with NACE requirements.
Inspection
17.1
Package systems shall be subject to random inspection by a Saudi Aramco
Vendor Inspection Department representative.
17.2
The Package System Supplier shall furnish all facilities, utilities, and test
equipment to accomplish factory acceptance tests.
17.3
Package systems shall be thoroughly inspected by a Saudi Aramco Vendor
Inspection Department representative. Representative shall witness all packaged
system tests and operation of all packaged systems as related to inspection
forms.
Packing/Shipping/Storage
18.1
Analyzer packaged systems shall be packaged or prepared for safe delivery to its
final destination.
18.2
A suitable desiccant or silica gel shall be placed inside all electronic enclosures
to protect electronics from humidity damage during shipment.
18.3
Special precaution shall be taken with fragile or sensitive equipment during
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shipment; such equipment shall be packaged separately if deemed necessary.
19
18.4
All lines shall be cleaned and dried with clean air or nitrogen and shall be
plugged or capped prior to shipment to prevent foreign material intrusion.
18.5
All valves shall be in closed position and flange connections shall covered with
metal cover plates.
18.6
Equipment or items that may move, shift, or vibrate during shipment must be
properly secured or supported to prevent damage during shipment.
18.7
All analyzer equipment or items shall be packaged or protected for extended
period storage or at the jobsite site. Electronic analyzer equipment located
inside analyzer shelters or analyzer cabinets that require humidity, moisture, or
climate control shall have their HVAC systems temporarily powered during
storage or placed in a climate controlled environment at the jobsite.
Documentation
19.1
Shelter or analyzer cabinet layout drawings shall be provided by the analyzer
shelter integrator and approved by the proponent organization. The drawings
shall include a plan views of the entire shelter or cabinet with analyzer locations,
doors locations, HVAC unit locations, and other ancillary equipment locations.
19.2
A set of documentation shall be prepared by the supplier for each sample
conditioning system indicating the position of components on the mounting
plate, interconnections and installation details as well as bill of materials for all
materials associated with each system.
19.3
An engineering drawing for each analyzer indicating the complete schematic
from sample point, preconditioning, sample line, sample conditioning, analyzer,
vent/drain and return lines shall be provided. Information on stream switching
valve operation, process conditions, line sizes, connections, and settings shall be
included on the drawings.
19.4
Analyzer Manufacturer/Analyzer System Integrator shall supply procedures for
start-up, shutdown, operation, and maintenance of the sample conditioning
systems.
19.5
Hardcopy documents shall be compiled into a binder complete with cover sheet,
index sheet, bill of materials, technical information, engineering drawings, and
test certificates. Electronic copy of the same documents arranged in similar
arrangement shall be provided in electronic format.
19.6
Analyzer Manufacturer/Analyzer System Integrator shall submit the compiled
drawings for review and approval from proponent before start of manufacturing
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of sample handling systems.
19.7
As-built drawings shall be submitted in hard copy and electronic copy,
minimum three copies each to Saudi Aramco.
19.8
All process analyzers shall be provided with the manufactures technical manuals
and electronic circuit drawings.
Revision Summary
15 September 2016
1 January 2018
New Saudi Aramco Engineering Standard that defines the minimum mandatory
requirements governing the design, installation, and safety of process analyzer equipment.
Editorial revision to delete paragraph 7.4.43.
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