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PETRONAS TECHNICAL STANDARDS

DESIGN AND ENGINEERING PRACTICE

MANUAL

ON-LINE PROCESS STREAM ANALYSIS SAMPLE CONDITIONING

PTS 32.31.50.11

DECEMBER 2007

2010 PETROLIAM NASIONAL BERHAD (PETRONAS)All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic,

mechanical, photocopying, recording or otherwise) without the permission of the copyright owner

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PETRONAS TECHNICAL STANDARDS

DESIGN AND ENGINEERING PRACTICE

(CORE)

MANUAL

ON-LINE PROCESS STREAM

ANALYSIS -

SAMPLE CONDITIONING

PTS 32.31.50.11

SEPTEMBER 2002

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PREFACE

PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication,of PETRONAS OPUs/Divisions.

They are based on the experience acquired during the involvement with the design, construction,operation and maintenance of processing units and facilities. Where appropriate they are basedon, or reference is made to, national and international standards and codes of practice.

The objective is to set the recommended standard for good technical practice to be applied byPETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemicalplants, marketing facilities or any other such facility, and thereby to achieve maximum technicaland economic benefit from standardisation.

The information set forth in these publications is provided to users for their consideration anddecision to implement. This is of particular importance where PTS may not cover everyrequirement or diversity of condition at each locality. The system of PTS is expected to besufficiently flexible to allow individual operating units to adapt the information set forth in PTS totheir own environment and requirements.

When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for thequality of work and the attainment of the required design and engineering standards. Inparticular, for those requirements not specifically covered, the Principal will expect them to followthose design and engineering practices which will achieve the same level of integrity as reflectedin the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from hisown responsibility, consult the Principal or its technical advisor.

The right to use PTS rests with three categories of users :

1) PETRONAS and its affiliates.2) Other parties who are authorised to use PTS subject to appropriate contractual

arrangements.

3) Contractors/subcontractors and Manufacturers/Suppliers under a contract withusers referred to under 1) and 2) which requires that tenders for projects,materials supplied or - generally - work performed on behalf of the said userscomply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements withusers, PETRONAS disclaims any liability of whatsoever nature for any damage (including injuryor death) suffered by any company or person whomsoever as a result of or in connection with theuse, application or implementation of any PTS, combination of PTS or any part thereof. Thebenefit of this disclaimer shall inure in all respects to PETRONAS and/or any company affiliatedto PETRONAS that may issue PTS or require the use of PTS.

Without prejudice to any specific terms in respect of confidentiality under relevant contractual

arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed byusers to any company or person whomsoever and the PTS shall be used exclusively for thepurpose they have been provided to the user. They shall be returned after use, including anycopies which shall only be made by users with the express prior written consent of PETRONAS.The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safecustody and PETRONAS may at any time require information satisfactory to PETRONAS in orderto ascertain how users implement this requirement.

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PTS 32.31.50.11September 2002

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TABLE OF CONTENTS

1. INTRODUCTION .......................................................................................................51.1 SCOPE .......................................................................................................................51.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ........51.3 DEFINITIONS ............................................................................................................51.4 ABBREVIATIONS ......................................................................................................61.5 CROSS-REFERENCES ............................................................................................61.6 SUMMARY OF REVISIONS FROM PREVIOUS EDITION .......................................72. GENERAL ..................................................................................................................83. SPECIFICATIONS FOR SAMPLE CONDITIONING SYSTEMS ..............................93.1 GENERAL ..................................................................................................................93.2 SPECIFICATION OF COMPONENTS ......................................................................93.3 FLOW RATE TO ANALYSERS ...............................................................................113.4 COOLING AND HEATING OF SAMPLES ...............................................................113.5 TEST AND CALIBRATION VESSELS .....................................................................113.6 MOUNTING ARRANGEMENTS ..............................................................................123.7 ANALYSER SYSTEM INTEGRATOR .....................................................................134. SPECIAL APPLICATIONS ......................................................................................144.1 GENERAL ................................................................................................................144.2 OXYGEN SERVICES ..............................................................................................144.3 CORROSIVE SERVICES ........................................................................................144.4 TOXIC AND NOXIOUS SERVICES ........................................................................144.5 SOUR SERVICES ...................................................................................................144.6 SHELL ANALYSER IMPLEMENTATION LOGIC (SAIL) .........................................154.7 CONTINUOUS EMISSION MONITORING SYSTEM (CEMS) ................................155. SAMPLE DISPOSAL SYSTEMS ............................................................................175.1 GENERAL ................................................................................................................175.2 GAS DISPOSAL TO FLARE ....................................................................................175.3 LIQUID DISPOSAL TO RECOVERY SYSTEM .......................................................175.4 LIQUID DISPOSAL TO EFFLUENT SYSTEM ........................................................175.5 VENT AND DRAIN SYSTEMS ................................................................................186. HEATING, WINTERIZING AND INSULATION .......................................................196.1 GENERAL ................................................................................................................196.2 HEATING AND WINTERIZING ................................................................................196.3 ELECTRIC HEATING ..............................................................................................196.4 INSULATION AND ENCLOSURE ...........................................................................197. REQUIREMENTS FOR ELECTRIC AND ELECTRONIC EQUIPMENT ................218. DRAWINGS .............................................................................................................229. TESTING AND INSPECTION ..................................................................................2310. REFERENCES ........................................................................................................2511. APPENDICES ..........................................................................................................27

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APPENDICES

APPENDIX 1 INDEX OF SAMPLE CONDITIONING SYSTEM DRAWINGS .......................28APPENDIX 2 TYPICAL SAMPLE CONDITIONING SYSTEM FOR OIL ANALYSERS .......29APPENDIX 3 COMPONENTS LIST OF THE SAMPLE CONDITIONING SYSTEM ............41APPENDIX 4 TYPICAL VENT AND DRAIN SYSTEM FOR ANALYSER HOUSES ............42APPENDIX 5 REFERENCE VESSEL FOR VALIDATION AND CALIBRATION

SERVICES ...................................................................................................44APPENDIX 6 FUNNEL AND SYPHON .................................................................................46APPENDIX 7 TYPICAL LAYOUT DRAWING OF SAIL ........................................................48

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1. INTRODUCTION

1.1 SCOPE

This PTS specifies requirements and gives recommendations for the design and

construction of sample conditioning systems for on-line process stream analysers and forthe disposal of sample fluids. This PTS is a revision of the PTS of the same number datedSeptember 1986.

This PTS is one of a series of on-line process stream analysis PTS.

The other publications are:

PTS 32.31.50.10, Sample take-off/transport;

PTS 32.31.50.12, Analysers;

PTS 32.31.50.13, Analyser Houses.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by PETRONAS, the distribution of this PTS is confined tocompanies forming part of PETRONAS or managed by a Group company, and toContractors nominated by them.

This PTS is intended for use in oil refineries, chemical plants, gas plantsexploration/production and supply/marketing installations.

If national and/or local regulations exist in which some of the requirements may be morestringent than in this PTS, the contractor shall determine by careful scrutiny which of therequirements are more stringent and which combination of requirements will be acceptableas regards safety, environmental, economic and legal aspects. In all cases, the Contractorshall inform the Principal of any deviation from the requirements of this PTS which isconsidered to be necessary in order to comply with national and/or local regulations. ThePrincipal may then negotiate with the Authorities concerned with the objective of obtainingagreement to follow this PTS as closely as possible.

1.3 DEFINITIONS

1.3.1 General defini tions

The Contractor is the party that carries out all or part of the design, engineering,procurement, construction, commissioning or management of a project or operation of afacility. The Principal may undertake all or part of the duties of the Contractor.

The Manufacturer/Supplier is the party that manufactures or supplies equipment andservices to perform the duties specified by the Contractor.

The Principal is the party that initiates, and ultimately pays for, the project. The Principalwill generally specify the technical requirements. The Principal may also include an agentor consultant, authorised to act for the Principal.

The word shallindicates a requirement.

The word shouldindicates a recommendation.

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1.3.2 Specific defini tions

Pipe Sizes: The international nomenclature Diameter Nominal written asDN 15, 25, 40, 50, etc.

Data/Information Where indicated as 'specified by the Principal' shall form a partof the requisition.

Stainless Steel AISI type stainless steel

Analyser systemhouse integrator

Contractor who specialises in providing one-stop integratedservices for all design, engineering, procurement, testing andcommissioning of an analyser package.

Heated Box A prefabricated thermal insulated enclosure with heating facilitydesigned to house the analyser sampling components

1.4 ABBREVIATIONS

NACE National Association of Corrosion EngineersSAIL Shell Analyser Implementation Logic - A set of

QMI hardware and software designed toprovide automated validations of QMIs in OilMovements area in accordance withASTM D 3764 philosophy.

AMADAS Analyser Maintenance And Data AcquisitionSystem

CEMS Continuous Emission Monitoring System - Ananalyser package specially designed to providecontinuous monitoring and record of stack

emissions.QMI Quality Measuring Instruments

NIR Near Infrared

1.5 CROSS-REFERENCES

Where cross-references to other parts of the PTS are made, the referenced section numberis shown in brackets. Other documents referenced by this PTS are listed in(10).

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1.6 SUMMARY OF REVISIONS FROM PREVIOUS EDITION

The previous edition of this PTS was dated September 1986. Other than editorial revisions,the following are the main changes to that edition:

Old section New Section Change

4.6 Added SAIL

4.7 Added CEMS

Appendix 1 Deleted

Appendix 1 Index of typical sample conditioning system drawings

Appendix 2 Simplified and made more selective.

Appendix 3 Deleted

Appendix 3 Was Appendix 7 in the last PTS

Appendix 7 Relocated to Appendix 3

Appendix 7 Added Typical layout drawing of SAIL

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2. GENERAL

Sample conditioning systems should be designed and constructed as described in (3).Typical drawings of sample conditioning systems for some commonly used analysers areattached in (Appendix 2). Depending on the application, users may adapt or modify the

drawings to suit the local environment and the properties of the process samples to beanalysed.

The materials of construction should be stainless steel. However, for oxygen, corrosive ortoxic/noxious services, other materials and/or additional provisions should be considered,see (4).

Sections (4.6)and (4.7)describe SAIL & CEMS complex analyser systems requirements.These should be customised for the specific needs of the site or project specifications. Atypical layout drawing of SAIL is given in (Appendix 7).

Sample disposal systems are described in (5)and typical details of a vent and drain systemare given in (Appendix 4).

Heating, winterizing and/or insulation requirements are given in (6).

The requirements for electric and electronic equipment are specified in(7).

Detailed drawings shall be prepared, as set out in (8).

The requirements for testing and inspection are given in(9).

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3. SPECIFICATIONS FOR SAMPLE CONDITIONING SYSTEMS

3.1 GENERAL

The sample conditioning system shall be designed to supply the sample at the analyser

inlet whilst meeting the conditions as specified in the analyser technical specifications. Itshall be designed so that none of the samples analytical properties are altered between thesample take off and analyser inlet. Utility connections or supplies such as air, cooling water,coolant, carrier gas and flushing oil, etc., shall be taken into consideration in the design ofthe sample conditioning system after the suitable type of analyser has been chosen for theintended application.

Depending on the application, a sample conditioning system will consist of the followingcomponents:

- filter(s);

- pressure gauge(s) & reducer(s);

- flow meter(s);

- isolation ball valve(s), needle valve(s), relief valve(s), selection valves and automatedvalves;

- temperature gauge/dial or temperature controller;

- multi-stream switching valve;

- excess flow check valve;

- cooler(s) and refrigerated chillers;

- heater(s) for heating or preventing freezing;

- vessel(s) for test/calibration services;

- sample pump(s);

- sample recovery system;

- utility connections/supplies such as air, steam, cooling water, carrier gas, flushing oil,etc.;

- tubing and compression fittings etc.

A sample conditioning rack/panel from the analyser manufacturer may be used. Sampleconditioning systems may be located in the field or at the analyser house, depending on thelocation of its associated analyser, see PTS 32.31.50.12 The sample conditioning systemfor a moisture analyser shall be field-mounted with its sample transport line as short aspracticable. The sample conditioning system for an H2S/SO2 analyser shall be close

coupled, housed in a heated box directly mounted on top of the process line with a steamjacketed isolation valve.

The sample transport system shall normally be a fast loop system with bypass and isolationvalves at the sample conditioning system. Single line sample transport systems may alsobe used for certain applications, see PTS 32.31.50.10 Stainless steel sample transportlines shall not be run next to galvanised pipes or come into contact with any galvanisedstructure support to avoid corrosion.

For typical examples, see (Appendix 2).The selected make(s) and type(s) of componentshall be as specified in the requisition.

3.2 SPECIFICATION OF COMPONENTS

All components selected shall be rated for the relevant process conditions. For generalapplications, all wetted parts shall be of stainless steel. The make(s) and type(s) ofcomponents, tubing and compression fittings shall be as specified by the Principal.

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Preference shall be given to components with compression fitting-ends, if specified in therequistion, manufactured by the same compression fitting Manufacturer.

The design pressure of components and tubing shall be in accordance withANSI/ASME B31.3. The design pressure for sample conditioning systems provided with arelief valve, referred to the pressure level at which the relief is installed, shall be not lessthan:

- for MOP between atmospheric and 17 bar (ga) = MOP + 1.7 bar;

- for MOP between 17 bar (ga) and 40 bar (ga) = 110 % of MOP;

- for MOP between 40 bar (ga) and 80 bar (ga) = MOP + 4 bar;

- for MOP above 80 bar (ga) = 105 % of MOP;

where MOP is defined as Maximum Operating Pressure.

Special attention shall be paid to the pressure ratings and the tolerances for outsidediameter and wall thickness of the tubing. The tubing shall meet the requirements ofISO 4200 for metric sizes and, when applicable, ASTM A 269 for imperial sizes.

The application of either metric or imperial sized tubing and compression fittings shall be

specified in the requisition.

The reliable application of compression fittings requires that:

- the fittings and tubing are installed strictly in accordance with the Manufacturer'sinstructions;

- the systems are pressure-tested after construction;

- it shall be ensured that imperial sized tubing and metric compression fittings or metricsized tubing and imperial compression fittings are not used in conjunction with oneanother because this will result in unreliable joints.

Sample conditioning systems shall have facilities for flushing, venting and/or draining, withvent and/or drain valve(s). The vent/drain outlets shall be connected to a vent or a drainsystem (5.5).

Instrument air supply lines and pneumatic signal lines should normally be made up frompolyvinylchloride (PVC) covered copper tubing and brass compression fittings andcomponents. However, if specified by the Principal, the air supply and signal lines shall bemade up from stainless steel tubing and stainless steel compression fittings.

NOTE: Mixing of different materials, e.g. brass and stainless steel, is not permitted.

Steam heating circuits for heat tracing of a sample line or heated box should normally be0.25 in. or 0.375 in. copper tubing, with brass compression fittings and components, andalso equipped with a steam trap to drain off condensate.

If specified by the Principal, supply lines for nitrogen, carrier gas and cooling water shallalso be colour coded.

Pressure gauges for sampled fluids should have a 50-mm dial and be provided with a0.25 in. threaded connection. The type of thread shall be as specified in the requisition.

Pressure gauges which can be depressurized in the conditioning system shall be installedon a gauge adapter or connected to a 0.5 in. female threaded compression fitting,supported from the mounting plate.

Pressure gauges that cannot be depressurized in the conditioning system shall be providedwith isolate-and-vent valve facilities. The vent/drain outlet shall be connected to a vent ordrain system (5.5).

Instrument air supply and nitrogen supply lines shall be provided with a filter reducercomplete with a pressure gauge and back flow protection. The nitrogen reducer shall be ofthe non-bleeding type.

NOTE: Pressure gauges for reducers and filter reducers should have a 50 mm dial and shall be provided witha 0.25 in. NPT threaded connection.

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Special attention shall be paid to the following:

- Solenoid valves shall be used only for switching instrument air and nitrogen. For allother fluids a pneumatically operated valve in combination with a solenoid valve shall beselected. The pneumatic actuator shall be provided with a direct-coupled mechanicalposition indicator.

- Glass components or parts should not be used for flammable and toxic/noxious fluids. Ifall stainless steel components for a particular range and/or duty are not commerciallyavailable, the Contractor/Manufacturer shall obtain written agreement from the Principalto use glass-containing components. If utilized, glass or glass-containing componentsshall be suitable for 1.5 times the maximum operating pressure of the related systemand shall be provided with 5-mm thick polycarbonate screens for personnel protection.Deviation requires the written approval of the Principal.

NOTE: Variable-area flow meters shall have a metal metering tube.

- Relief valve(s) shall be installed to protect those components installed in a system whichhave a limited pressure rating, e.g., sample conditioning vessels and glass-containing

components. The relief valves shall be connected to a vent or a drainage or flare systemas required.

3.3 FLOW RATE TO ANALYSERS

An excess flow valve shall limit the total amount of flammable fluids flowing to the analyser.

The following requirements shall be met:

- the maximum flow rate of flammable gases shall not exceed 20 Nl/h;

- the liquid flow rate shall not exceed the maximum required flow rate, as specified by theManufacturer of the analyser concerned.

NOTES: 1. Flow rates exceeding the above limits require the approval of the Principal in writing.

2. The excess flow valve shall be a self-closing type to prevent the above limits from beingexceeded.

3.4 COOLING AND HEATING OF SAMPLES

Cooling or heating as appropriate shall be provided in the sample conditioning system foranalysers requiring a sample inlet temperature within specified limits.

Where cooling is required, fresh water from the main cooling system or industrial watershould be used. Seawater shall not be used as a cooling medium.

NOTE: The maximum temperature of the cooling water supply during hot seasons and in tropical locationsshall be the design temperature.

If the cooling water temperature is too high, cooling by means of cold air from a vortex tubeor by refrigeration or other mechanical cooling shall be considered. However, the use ofrefrigerated or mechanical coolers requires the written approval of the Principal. Forrefrigerated coolers, an electric motor with single-phase power supply according to the sitestandard should be used. The use of three-phase power supply requires the approval of thePrincipal.

If heating is required to lower the viscosity or to prevent condensation of gaseous samplesor absorption in materials, the application shall be in accordance with (6).

3.5 TEST AND CALIBRATION VESSELS

A vessel shall be provided for analysers that require liquid samples for testing andcalibration. Depending on applications and requirements, calibration vessels may be of

different sizes and may be custom built or supplied by Manufacturer/Suppliers as astandard item. The capacity of the calibration vessel should be sized so that frequent

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topping up of reference standard/sample is not necessary. Depending on the checkfrequency and usage/wastage of the reference standard, the capacity of the calibrationvessel should be sufficient to hold a batch of reference standard for 3 months beforereplenishment is necessary.

If heat is required to lower the viscosity or to prevent freezing of the liquid, a stainless steelsteam heating coil shall be installed around the vessel. If steam is not available, electricalheating tape of the self-regulating type should be applied.

The thermal insulation around vessel and heating facilities shall have a guaranteedmaximum chloride content of 10 mg/kg and be sealed against water ingress in order toprevent chloride stress corrosion.

Piston type sample calibration vessels could be considered as an alternative to the vesseldescribed in(Appendix 5).

Where nitrogen is used as a pressurising medium, the pressure should not exceed0.5 bar (ga) and a miniature pump should be used to pressure up sample delivery to theanalyser.

3.6 MOUNTING ARRANGEMENTS

All components shall be installed on a stainless steel mounting plate, secured to the sampleconditioning rack with flat, countersunk headed stainless steel bolts.

The sample conditioning rack shall be selected from one of the following types:

- freestanding;

- floor mounting (which will require additional support);

- wall mounting,

and constructed in accordance with one of the following methods:

- welded, all material of stainless steel;

- welded, all material of carbon steel, hot-dip galvanized in accordance with therequirements of ASTM A 123 or BS 729, after drilling and welding. The nuts shall beretapped after galvanizing;

- bolted, all materials of prefabricated stainless steel, U or H profile, with mountingstrips/plates, bolts and nuts.

NOTE: The Manufacturer/Supplier shall design the conditioning rack(s), mounting plate(s) and support(s) forthe total weight of all the components including the weights of fluid(s).

Components should be attached to the mounting plate with bolts and nuts, the nuts beingpermanently fixed to the mounting plate. Special attention shall be paid to the position ofthe components in relation to the connections to be made.

NOTE: Components such as ball valves and non-return valves may be supported by their connecting tubingby means of stainless steel attachments adjacent to the tubing connections. Non-metallic spacermaterial, e.g., teflon hose, shall be used to isolate the tubing from the supports.

Components such as filters, coalescers and flow cells/electrodes that require frequentmaintenance should be mounted at a suitable height and be easily accessible.

Bulkhead unions shall be supported from the mounting plate. The lock nut shall be locatedon the conditioning side of the system.

Prefabricated sample conditioning systems shall be supplied with engraved nameplates inaccordance with PTS 32.31.00.32 The nameplates should be fixed directly to the mountingplate but if their descriptions may be obstructed by components and/or tubing, a separatenameplate support shall be provided attached to the mounting plate. Nameplates shall befixed to the supports with stainless steel screws.

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All incoming and outgoing connections shall be identified with engraved nameplates.Components such as relief valves, excess flow valves and variable-area flow meters shallalso be provided with nameplates showing their settings.

In addition to the above, incoming and outgoing connections at thermal insulationenclosures for sample conditioning systems, shall be provided with nameplates on theoutside of the enclosure.

Analysers mounted outdoors and susceptible to direct sunshine shall be installed with anappropriate sunshade.

Compression fittings shall be provided with parallel threaded connections.

NOTE: The thread surfaces require lubrication with a suitable compound.

The compression fitting shall be locked to the body of the relevant component with alocking pin.

NOTES: 1. NPT threaded compression type elbows shall not be used, because the length of engagement ofthe threads is considered insufficient when correct alignment is obtained.

2. NPT threaded connections require special provisions to prevent seizing and leakage.

For temperatures between -100 C and +200 C, PTFE tape (MESC 85.15.78.038.1) shall beapplied as follows:

- Place tape on the male thread, leaving two threads at the small end free from tape, hold inplace and wrap clockwise once only with a half tape width overlap. Draw tightly around thethreads so that it conforms to the threaded surface.

The tubing shall be arranged so that the removal of one component will not require thedismantling of other parts. The components shall also be installed in different planes toavoid the need for bends when crossings have to be made.

The tubing shall be cut dead square with a tube cutter and the tube edges shall bedeburred. The tube end shall be undamaged, round and without scratches over the lengthwhich fits into the compression fitting. Any coating or painting shall be removed.

The tubing shall be bent with a high-quality tube bender to at least the minimum bendingradius as specified by the tubing Manufacturer.

NOTE: Special attention shall be paid to tubing made of other materials such as Monel, Hastelloy or Incoloy(4.3). The recommended minimum bending radii for tubing in these materials may be larger than thosespecified for stainless steel.

3.7 ANALYSER SYSTEM INTEGRATOR

Analyser system integrators are specialist contractors providing one-stop integratedservices for all design, engineering, procurement, testing and commissioning activities of ananalyser system, including optional fabrication of analyser houses to clients requirements.Qualified analyser system integrators shall be contracted as far as possible to design

sampling systems as part of the total analyser system package.

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4. SPECIAL APPLICATIONS

4.1 GENERAL

To ensure an efficient operation of the sample conditioning system under all operational

and climatic conditions, certain applications require provisions in addition to, or in deviationfrom those specified in (3), e.g., the use of special materials and/or components andheating(6),or a combination thereof.

4.2 OXYGEN SERVICES

All materials for gaseous-oxygen applications shall be carefully degreased and inspected inaccordance with the requirements of PTS 31.10.11.31

4.3 CORROSIVE SERVICES

For applications where stainless steel is not suitable, preference shall be given to materialssuch as Monel, Hastelloy or Incoloy.

When components made of the above materials cannot be commercially obtained, thenTeflon may be considered.

The application of any of the above materials requires the written approval of the Principal.

4.4 TOXIC AND NOXIOUS SERVICES

All vents for toxic and/or noxious services shall be connected to a vent for toxic products oralternatively to a flare system. If the quantity of toxic and/or noxious process sample beingreleased from the vents is below the acceptable limit as advised by the Principal and/orindicated in the Project Specifications, it may be released to the atmosphere at a safeheight and in a safe direction. In this case, written approval of the Principal shall berequired.

All drains shall be directed to a drainage vessel or a covered pit allocated to receive toxicproducts.

The sample conditioning system shall have flushing facilities terminating in a valve with acompression fitting. An armoured hose or coiled tubing, provided with compression fittingends, should be used to flush the components and tubing. When the flushing connection isnot in use it shall be closed with a compression fitting type plug, secured by means of abead-type chain to the compression fitting or to the isolating valve body.

The sample conditioning system shall be provided with a red nameplate bearing theinscription in white:

CAUTION: TOXIC/NOXIOUS SERVICE

The nameplate shall be in accordance with the requirements of PTS 32.31.00.32, but shallbe screwed and not glued. The letter height shall be 20 mm.

4.5 SOUR SERVICES

Amended perCircular 38/04

All components installed in sour services shall comply with the requirements ofPTS 31.38.01.11

Sour services or sour environments are defined as fluids containing water as a liquid andhydrogen sulphide exceeding the limits prescribed in ISO 15156 or NACE MR0103, as

applicable. These environments may cause sulphide stress cracking of susceptiblematerials.

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NOTES: 1. ISO 15156 shall apply to oil and gas production facilities and natural gas sweetening plants.NACE MR0175 is equivalent to ISO 15156.

2. NACE MR0103 shall apply to other applications (e.g. oil refineries, LNG plants and chemicalplants).

If components cannot be obtained in accordance with the the above standards, Hastelloy-Cor type 17-4 PH stainless steel should be used.

Typical examples are:

- valve head spindles;

- compression fittings.


The wetted parts of the components shall meet the hardness requirements of ISO 15156 orNACE MR0103, as applicable (see above).

The application of complete components made of Hastelloy-C requires the written approval

of the Principal.The threads of screwed components shall be coated with a lubricant/sealing material beforeinstallation to prevent corrosion.

4.6 SHELL ANALYSER IMPLEMENTATION LOGIC (SAIL)

The Shell Analyser Implementation Logic (SAIL) is based mainly on ASTM D 3764, thestandard method for analyser validation using the reference sample method. SAIL isnormally used for QMIs in the blenders as part of a Quality Release system. SAIL consistsof a set of QMI system hardware and SAIL software. For each QMI application, the SAILsoftware module must be specified according to the local operational philosophy andASTM D 3764. When an on-line NIR analyser is used, validation shall be based onASTM D 6122.

SAIL software is implemented by DCS Manufacturers/Suppliers and specialist SAILImplementation Suppliers.

Sample system component selection and design for SAIL shall be specified as part of aSAIL implementation project. A functional specification will form the basis for detailedengineering for SAIL. Reports MF 94-0515, OP 97-30425 and OP 00-30408 provideguidelines for the formulation of such a functional specification. This PTS shall be used tomeet the requirements for sample conditioning.

A qualified analyser system integrator shall be contracted to design and supply thesampling system and components. Pre-qualified DCS or SAIL Implementation Suppliers willsupply the SAIL logic. Any communication link between the SAIL and DCS systems will bein the scope of supply of the DCS Supplier. The integrated operation of the SAIL logic and

sampling system shall be specified to be tested by and be in the scope of the MainAutomation Contractor for major projects, or the SAIL logic Supplier for a stand-alone SAILimplementation project.

A SAIL application shall be supplied with a full as-built program listing of the logic. Thelisting shall include commentary text to clarify the logic. Additionally, a flow sheet indicatingthe full logic sequence shall be provided.

4.7 CONTINUOUS EMISSION MONITORING SYSTEM (CEMS)

For CEMS, there are two types of sampling techniques used, i.e. extractive and in-situ.

Extractive method:

A gas sample shall be continuously extracted from the stack, filtered to remove theparticulate content and all the water vapour to provide a dry measurement, or heated withthe water vapour retained to provide a wet measurement.

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5. SAMPLE DISPOSAL SYSTEMS

5.1 GENERAL

Samples should be returned to the process stream.

For those applications where other arrangements are required for technical reasons, thesamples should be directed to one of the following:

- a flare system;

- a recovery system;

- an effluent system.

Waste samples and/or by products of the analysis process shall not be discharged toatmosphere unless approved by the Principal. Exemptions are air and moderate amountsof hydrogen, e.g., column vent of a gas chromatogram, nitrogen and other non-toxic and/ornon-odorous compounds that are considered as safe and non-hazardous for theenvironment.

If waste gases or vapours cannot be returned to one of the above systems they should bevented to the atmosphere in such a way that:

- they are discharged at a safe height and in a safe direction;

- flammable conditions are not created;

- the number of venting points is limited to a minimum.

For typical vent details, see (Appendix 4).

Venting to atmosphere requires the Principal's written approval.

5.2 GAS DISPOSAL TO FLARE

Hydrocarbon gases or vapours which cannot be returned to the process should bedischarged to a flare system, via a non-return check valve.

Flare systems normally operate at varying pressures; the Principal shall specify themaximum operating pressure.

The effluent gas pressure shall be kept constant by means of a back-pressure regulator.

5.3 LIQUID DISPOSAL TO RECOVERY SYSTEM

Hydrocarbon liquids that cannot be returned to the process shall be discharged into one ofthe following systems:

- plant hydrocarbon recovery system;

- drain pit for hydrocarbon products.The total quantity of liquids disposed of shall be limited to the minimum necessary foradequate sampling. Liquid hydrocarbons with low boiling point which can easily vaporise atambient temperature should not be discharged to an open drain.

5.4 LIQUID DISPOSAL TO EFFLUENT SYSTEM

Aqueous effluents shall be disposed of via one of the following dedicated effluent systems:

- 'clean effluent' for aqueous fluids which are always clean;

- 'normally clean effluent' for aqueous fluids which are normally clean but may becomecontaminated in emergencies;

- 'contaminated effluent'.

NOTE: Aqueous fluids from analysers using reagents shall be discharged into contaminated effluent systems.

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At locations where there is no dedicated effluent system, non-toxic and/or non-noxiousaqueous effluents, such as boiler feed water or de-mineralised water, may be discharged tothe ground or the nearest drain.

5.5 VENT AND DRAIN SYSTEMSVent and drain systems should be installed in the conditioning area against the outsidewall(s) of the analyser house and should be adequately supported at maximum intervals of1 m.

The vent and drain systems will be selected by the Principal from the following options tosuit the application:

- carbon steel, all-welded construction;

- stainless steel, AISI type 316, all-welded construction or with compression fittings;

- rigid PVC plastic, cemented construction in accordance with the requirements ofPTS 31.38.01.12

The minimum size of the piping for vent header(s) shall be DN 50 and for liquid headersDN 80. The interconnecting piping shall be minimum DN 15.

Connections to drain headers without an isolating valve shall be provided with a gooseneck liquid seal. Where required, a funnel syphon for liquid seal shall be installed, see(Appendix 6).

Special attention shall be given to ensure the segregation of water and oil drain headers,(5.3)and (5.4).

NOTE: Cooling water shall not be discharged into condensate return systems.

For a typical example of a vent and drain system, see(Appendix 4).

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6. HEATING, WINTERIZING AND INSULATION

6.1 GENERAL

Heating of sample conditioning systems, if required, should preferably be by steam. If

steam is not available, or if specifically requested by the Principal, electric heating shall beapplied. A prefabricated thermal insulating enclosure with heating facilities (heated box)shall be provided to house the sampling components. Where sample lines enter or leavethe heated box, insulating grommets or similar shall be installed to avoid metal to metalcontact with the enclosure. Proper installation/insulation procedures shall be applied for theheat traced sample lines to avoid ingress of rainwater.

Open drains, such as funnels, shall be installed outside the enclosure.

Electric and electronic components, such as solenoid valves, switches and timer devices,should not be installed inside the enclosure.

All electrical and electronic components shall meet the requirements specified in(9).

6.2 HEATING AND WINTERIZING

Low-pressure steam at 3.5 bar (ga) should be used for heating purposes. If highertemperatures are required, medium-pressure steam up to 18 bar (ga) may be considered.

The steam heating shall be arranged so that the heating equipment does not obstruct othercomponents.

Sample conditioning systems that operate at constant temperature shall be provided with aself-acting temperature controller installed in or on top of the enclosure.

A temperature gauge of dial size 50 mm shall be installed in the door with the indicatoroutside the enclosure.

Each sample conditioning system shall have its own steam supply, complete with isolatingvalves labelled with the tag number of the system. The valves shall be installed outside the

enclosure.

Each steam header shall terminate in a condensate return line. Steam supply andcondensate return lines form part of Mechanical Engineering.

6.3 ELECTRIC HEATING

Electric heaters shall be provided with a thermostat that controls the temperature within 3 C of the required setting. Alternatively, self-regulating heating tape may be used. Allelectric equipment shall meet the requirements specified in(9).The electric heating shall bearranged so that the heating equipment does not obstruct other components.

6.4 INSULATION AND ENCLOSURE

The type of enclosure shall be as specified by the Principal.Sample conditioning systems provided with heating facilities shall have enclosures that areconstructed from glass-fibre-reinforced polyester or from stainless steel plates insulatedwith mineral wool. The enclosure shall meet the requirements of IP 65 to prevent rainwateringress.

The chloride content in the mineral wool insulation should not exceed 10 mg/kg.

The enclosures shall be provided with a door in the front. Enclosures in which thetemperature needs to be kept above 50 C shall be provided on the front of the door with ared nameplate bearing the inscription in white:

CAUTION: HIGH-TEMPERATURE SERVICE

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The nameplate shall be in accordance with the requirements of PTS 32.31.00.32, but shallbe screwed and not glued. The letter height shall be 20 mm.

Hinges and locks shall be made of stainless steel.

NOTE: Special attention shall be paid to the installation of the mounting plate inside the enclosure and to the

accessibility of components.

Vent, drain and condensate return lines may also require insulation and/or heat tracing toprevent freezing.

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7. REQUIREMENTS FOR ELECTRIC AND ELECTRONIC EQUIPMENT

Unless otherwise specified, all electric and/or electronic equipment shall have a type ofprotection adequate for the zone in which they are installed.

For open ventilated areas, components shall have a minimum Zone 2 classification.

Electric equipment installed inside the sample conditioning enclosure shall meet therequirements of IEC 60079-14 and shall:

- have a type of protection adequate for Zone 2, if the sources of release do not containflammable substance;

- have a type of protection adequate for Zone 1, if only secondary grade sources ofrelease of flammable substance are present;

- have a type of protection adequate for Zone 0, if primary grade sources of release offlammable substance are present.

NOTES: 1. The use of non-ventilated sample systems with primary grade sources of release requires writtenapproval of the Principal.

2. Continuous grade sources of release of flammable substance are not permitted.

3. Components without a type of protection adequate for Zone 2 shall be installed in the analyserhouse, see PTS 32.31.50.12 and be located close to the relevant analyser.

4. For details of area classification, refer to IEC 60079-10.

The sample conditioning rack, the mounting plate, and if applied, the stainless steelenclosure shall each be provided with a brass M8 earthing bolt.

All electrical equipment shall be connected to the plant earth by an insulated wire forpersonnel protection. The colour coding of the insulation shall be yellow/green.

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9. TESTING AND INSPECTION

The Manufacturer/Supplier shall pressure test and inspect the sample conditioning systembefore offering the system for inspection by the Principal or the Principals representative.

The Manufacturer/Supplier shall make available for the test and/or inspection:

- sufficient qualified labour to perform the test;

- air or nitrogen at a minimum pressure of 10 bar (ga) for the full duration of thetest/inspection;

- air bubbler, maximum working pressure 10 bar (ga);

- a leak detector,

- measuring equipment for supplies and outputs;

- special measuring tools/equipment for components installed;

- power supply units as applicable, e.g. 24 V DC and 220 V AC;

- three copies of the as-built drawings.NOTE: The Manufacturer/Supplier shall ensure that all documentation, including material and/or construction

certificate(s) for vessel(s) and/or components as applicable, is available before inspection starts.

The system shall be checked against the as-built drawings and the requirements of thisPTS. When applicable, the related certificates shall be checked or verified. Site inspectionand testing shall be carried out in accordance with PTS 62.10.08.11 and the Manufacturersown procedures. Attention shall also be paid on the ease of removal of samplingcomponents and all the associated taggings and markings.

The following tests and inspection procedures shall be performed:

1. Leak test

The complete system shall be leak-tested by pressurizing via a bubbler with air or

nitrogen at 1.1 times the design pressure of the system. If relief valve(s) form part of thesystem, the relief setting shall be the maximum applied pressure to test the system.

Inlets and outlets shall be capped off with the exception of those which are provided witha valve. The isolating valve shall be closed for these connections. All other valves andreducers shall be fully opened.

The maximum pressure applied shall not exceed 10 bar (ga).

The system shall be pressurized for at least 5 minutes, while the bubbler is carefullyobserved.

If there are signs of leakage, the Manufacturer/Supplier shall correct the leakingconnection(s)/component(s). Manufacturer/Supplier shall be liable to repair any leakageproblem on site when the sample conditioning system has been commissioned with

actual sample flowing at process conditions.

2. Hydrostatic test

Systems or parts of systems with a design pressure up to 9 bar (ga) shall be isolatedfrom other parts of the system having a higher design pressure, and shall be opened toatmosphere during the hydrostatic test.

Systems or parts of systems with a design pressure higher than 9 bar (ga) shall bepressurized at 1.5 times the design pressure via a tight shut-off valve and a high-qualitypressure gauge (error to be within 0.5 % of the maximum scale value in the range of10 % to 100 % of the scale).

NOTE: Fluids used for testing shall be compatible with the fluids to be analysed.

The pressure in the system shall remain constant for at least 10 minutes after the tightshut-off valve has been closed.

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The system shall be thoroughly dried with clean dry air or nitrogen after draining.

3. Function test

All electrical and electronic components shall be connected to the applicable powersupplies and shall be function-tested.

All pneumatic or electrically operated switching valves shall be tested to confirm thecorrect switching action and/or sequence as designed.

All components of a SAIL system shall be tested in accordance with the functionalspecifications.

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10. REFERENCES

In this PTS, reference is made to the following publications.

NOTE: Unless specifically designated by date, the latest edition of each publication shall be used, togetherwith any amendments/supplements/revisions thereto.

PETRONAS STANDARDS

Index to PTS publications and standardspecifications

PTS 00.00.05.05

Gaseous-oxygen systems PTS 31.10.11.31

Piping - general requirements PTS 31.38.01.11

Piping classes - refining and chemicals PTS 31.38.01.12

Instruments for measurement and control PTS 32.31.00.32

On-line process stream analysis:- Sample take-off and transport PTS 32.31.50.10

- Analysers PTS 32.31.50.12

- Analyser houses PTS 32.31.50.13

Electrical engineering guidelines PTS 33.64.10.10

Inspection and functional testing of equipment PTS 62.10.08.11

Analyser Maintenance And Data AcquisitionSystems (AMADAS)

OP 97-30425

Guidelines for Implementation of ASTM D 6122 OP 00-30408

Product Release Using QMIs MF 94- 0515

Materials and Equipment standards code (MESC)Buying Description 85.15.78.038.1

AMERICAN STANDARDS

Chemical Plant and Petroleum Refinery Piping

Issued by:The American Society of Mechanical Engineers,345 East 47th Street,New York 10017, USA

ASME B31.3

Specification for zinc (hot galvanized) coatings onproducts fabricated from rolled, pressed and forgedsteel shapes, plates bars and strip

ASTM A 123

Specification for seamless and welded austeniticstainless steel piping for general refinery service

Issued byAmerican Society for Testing and Materials,1916 Race St., Philadelphia,Pa. 19103, USA

ASTM A 269

Standard specification for stainless steel bars andshapes

ASTM A 276

Standard practice for validation of process streamanalyzers

ASTM D 3764

Standard practice for the validation of multivariateprocess infrared spectrophotometers

ASTM D 6122
http://00000505.pdf/http://31101131.pdf/http://31380111.pdf/http://31380112.pdf/http://32310032.pdf/http://32315010.pdf/http://32315012.pdf/http://32315013.pdf/http://33641010.pdf/http://62100811.pdf/http://62100811.pdf/http://33641010.pdf/http://32315013.pdf/http://32315012.pdf/http://32315010.pdf/http://32310032.pdf/http://31380112.pdf/http://31380111.pdf/http://31101131.pdf/http://00000505.pdf/

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Amended perCircular 38/04Issued by:

American Society for Testing and Materials100 Barr Harbor Drive, West Conshohocken,PA 19428-2959

USAMaterials resistant to sulfide stress cracking in corrosivepetroleum refining environments

NACE MR0103

Petroleum and natural gas industries Materials foruse in H2S-containing environments in oil and gasproduction

Issued by:NACE International1440 South Creek Dr.Houston, TX 77084-4906,USA

NACE MR0175

BRITISH STANDARDSHot dip galvanized coatings on iron and steel articles BS 729

Issued by:British Standards Institution2 Park Street,London W1A 2BS,United Kingdom

INTERNATIONAL STANDARDS


Petroleum and natural gas industries Materials for use inH2S-containing environments in oil and gas production

ISO 15156

Plain end steel tubes, welded and seamless -General tables of dimensions and masses per unitlength

Issued byInternational Organization for Standardization,1, rue de Varemb,Post Box 56,CH-1211 Geneve 20, Switzerland

ISO 4200

Electrical apparatus for explosive gas atmospheres:Part 10: Classification of hazardous areas IEC 60079-10

Part 14: Electrical installations in hazardous areas

(other than mines)

Issued by:Central Office of IEC (sales dept.)3, rue de Varemb,1211 Geneve 20, Switzerland

IEC 60079-14

Copies can also be obtained from most national standards organisations

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11. APPENDICES

AppendixIndex of typical sample conditioning system drawings 1Typical drawings of sample conditioning systems 2

Components list of the sample conditioning system 3Typical vent and drain system for analyser houses 4Reference vessel for validation and calibration services 5Funnel and Syphon 6Typical layout drawing of SAIL 7

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APPENDIX 1 INDEX OF SAMPLE CONDITIONING SYSTEM DRAWINGS

Typical liquid sample conditioning system for:

- Oil analysers (e.g. Colour, Flash point, Distillation, RVP) -Fast Loop

- Oil analysers (e.g. Flash point, Distillation, RVP) - Fast Loopwith Cooling Facility

- Oil analysers (e.g. Flash Point, Distillation) - Fast Loop andReference Vessel

- Oil analysers (e.g. Cloud Point, CFPP, Freeze Point,Viscosity) - Fast Loop, Cooling Facility and Reference Vessel

- Water analysers (e.g. pH, Conductivity) - Single Line- Water analysers (e.g. Dissolved Oxygen, Oil in Water) -

Single Line and Cooling Facility- Chromatograph - Fast Loop

Typical gas sample conditioning system for:

- Water content analyser- Density analyser- Oxygen (Zicronic type)- Chromatograph- O2, H2S, SO2, NOx, CO, CO2, analyser etc.

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APPENDIX 2 TYPICAL SAMPLE CONDITIONING SYSTEM FOR OIL ANALYSERS(Fast loop)

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TYPICAL SAMPLE CONDITIONING SYSTEM FOR OIL ANALYSERS(Fast loop with cooling facility)

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TYPICAL SAMPLE CONDITIONING SYSTEM FOR OIL ANALYSER(Fast loop with reference vessel)

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TYPICAL SAMPLE CONDITIONING SYSTEM FOR OIL ANALYSERS(Fast loop with cooling facility and reference vessel)

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TYPICAL SAMPLE CONDITIONING SYSTEM FOR WATER ANALYSERS(Single Line)

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TYPICAL SAMPLE CONDITIONING SYSTEM FOR WATER ANALYSERS(Single line with cooling facility)

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TYPICAL SAMPLE CONDITIONING SYSTEM FOR LIQUID ANALYSERS(Chromatograph)

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TYPICAL SAMPLE CONDITIONING SYSTEM FOR WATER CONTENT ANALYSER

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TYPICAL SAMPLE CONDITIONING SYSTEM FOR GAS DENSITY ANALYSER

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TYPICAL SAMPLE CONDITIONING SYSTEM FOR OXYGEN ANALYSER(Zirconia type)

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TYPICAL SAMPLE CONDITIONING SYSTEM FOR CHROMATOGRAPH ANALYSER

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TYPICAL SAMPLE CONDITIONING SYSTEM FOR GAS ANALYSERS(e.g. O2, H2S, SO2, Nox, CO, CO2, etc).

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APPENDIX 3 COMPONENTS LIST OF THE SAMPLE CONDITIONING SYSTEM

The Items refer to the drawings ofAppendix 2.

Item Description Size Item Description Size

BVH Ball valve 0 120 1/2

mm ODin OD

PRQ Pressureregulator

0 1/40 1/4

in BSPin NPT

BLV Block/bleedvalve

0 1/20 1/2

in BSPin NPT

PGH Pressuregauge

0 1/20 1/2

In BSPin NPT

GVH Globe valve 0 120 1/2

mm ODin OD

FIH Flow meter 0 1/20 1/2

in BSPin NPT

BVQ Ball valve 0 60 1/4

mm ODin OD

FIV Flow meter(with needlevalve)

0 1/40 1/4

in BSPin NPT

NVQ Needle valve 0 60 1/4

mm ODin OD

FIQ Flow meter 0 1/40 1/4

in BSPin NPT

CVQ Check valve 0 60 1/4

mm ODin OD

FCQ Flowcontroller

0 1/40 1/4

in BSPin NPT

BVS Ball valve3-way

0 60 1/4

mm ODin OD

EFV Excess flowvalve

0 1/40 1/4

in BSPin NPT

RVQ Relief valve 0 60 1/4

0 1/40 1/4

mm ODin OD

in BSPin NPT

TGQ Temperaturegauge

0 1/40 1/4

in BSPin NPT

FLF Fast loopfilter

0 1/20 1/2

in BSPin NPT

FNL Funnel 0 1/20 1/2

in BSPin NPT

BPF By-passfilter

0 1/40 1/4

in BSPin NPT

SPH Syphon 0 1/2 in NPT

STF Sintered filter 0 60 1/40 1/40 1/4

mm ODin ODin BSPin NPT

SGL Sight glass 0 1/20 1/2

in BSPin NPT

FCL Filter/coalescer

0 1/40 1/4

in BSPin NPT

RFV Referencevessel

ILF In-line filter 0 60 1/40 1/40 1/4

mm ODin ODin BSPin NPT

WCL Water cooler 0 1/40 1/4

in BSPin NPT

CLS Coalescer 0 1/40 1/4

in BSPin NPT

FPR Filter/regulator

0 1/40 1/4

n BSPin NPT

NOTE: Select the component required by placing a X in the 0

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APPENDIX 4 TYPICAL VENT AND DRAIN SYSTEM FOR ANALYSER HOUSES

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TYPICAL VENT AND DRAIN SYSTEM FOR ANALYSER HOUSE (Cont'd)

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APPENDIX 5 REFERENCE VESSEL FOR VALIDATION AND CALIBRATION SERVICES

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REFERENCE VESSEL FOR VALIDATION AND CALIBRATION SERVICES (cont'd )

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APPENDIX 6 FUNNEL AND SYPHON

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FUNNEL AND SYPHON (cont'd)

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APPENDIX 7 TYPICAL LAYOUT DRAWING OF SAIL

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