Process Analyzer Sampling Systems Simplified

| ASI Webinar | March 24, 2020 |
© Yokogawa Corporation of America
Live Webinar
Process Analyzer Sampling
Systems Simplified
Joe Goh
Product Manager
Analyzers & Analytical Systems Integration
Yokogawa Corporation of America
March 24, 2020 — 11am EST

Presenter
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Joe Goh
Analytical Product Manager
281-325-1871
Joe.Goh@yokogawa.com

You will learn:
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1. Key sampling system
components and functions
2. Examples of system designs,
various types of components
and when they are used
3. Best operation and maintenance
practices for optimizing sampling
system performance

Why do Plants need Process Analyzer Systems?
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n Maintain Quality of Products
n Maximize Yield
Regulatory
Requirement
Safety
n EPA regulates Excess Emission and
CEMS Monitoring Availability
n Monitor for toxic and flammable
chemicals
n Protect Plant personnel, public, and
equipment.
Process
Optimization

Traditional Plant Lab Analysis
n Results take 4-6 hours
n Sampling Discrepancy
n Different Analytical Technology
n Costs add up
u Cost of Lab Personnel/Equipment
u Delay of Process Results
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Traditional Plant Lab Analysis
n Results take 4-6 hours
n Sampling Discrepancy
n Different Analytical Technology
n Costs add up
u Cost of Lab Personnel/Equipment
u Delay of Process Results
5

Continuous Process Analysis
n In-Line, At-Line or In-Situ
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n Extractive Analysis

Major Analyzer System Components
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Key Sampling System Components
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Shelter Safety
System

Types Of Analyzer Mounting
u Popular for equipment suitable for
outside mounting;
e.g. Gas Density, pH/Conductivity
meters
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u Suitable for small single analyzers
up to CEMS type packages
u Minimal environmental / hazardous
area control
Panel Mounted BoxCabinet

Types Of Analyzer Enclosures
u Popular for larger analyzers in
temperate climates
u Open ventilation helps reduce
stringent hazardous area
classifications of mounted
equipment
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u Best protection of analyzer
hardware
u Best working environment
u Most expensive solution
3-Sided Shelter Walk-in Enclosed Shelter

Examples Of Shelter Construction
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Fiberglass Analyzer House Painted steel, SS, or Aluminum
Concrete Building

Shelter Design Considerations
n Wiring / cable management
u Conduit (popular in Western Hemisphere)
u Armored Cable (popular in Europe)
n Sample Systems on exterior
u Except in cold climates
n Split shelter
u Sample system section in cold climates
n Rainshields
u Covering sample systems and bottle racks
n Heated boxes for cal bottles
u Especially in cold climates
n Doors on each end for larger shelters
n Flooring
u No floors for mounting on cement pad
u Steel plate flooring for elevated installations
u Insulated flooring for extreme cold climates
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Hazardous Area Classification
n Determined by the end-user
u Based on their corporate safety guidelines
u Class, Division (Zone), Groups, T-Rating
n Compliance Standards
u NEC/NFPA (U.S.)
u CSA (Canada)
u ATEX (Europe)
u IECEx (Emerging Global Standard)
n Local Certification
u Paid certification by local agency representative
u Used for non-certified equipment
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Impact Of Rating On Analyzer Packaging
n Shelter hardware
u Electrical systems
Ø Breaker and junction boxes
Ø Lighting fixtures
Ø Power receptacles
u Air conditioning systems
u Pumps / Motors
n Analyzers
u Not all analyzers are rated for hazardous areas
n Purging of enclosure or entire shelter
u Reduces cost of internal components
u Makes maintenance easier (no hot work permits)
u Compliance to NFPA496; Z-Purge, Y-Purge, X-Purge
n Relocation of shelter inside plant may help reduce
impact of rating
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Shelter Safety Systems
n Safety systems monitor the conditions
inside the shelter
u LEL Combustible analyzers
Ø Especially when using purged shelter
u Toxic gas sensors (H2S, Cl2)
u Oxygen deficiency analyzers
Ø Common when plant nitrogen used by
analyzers
n Consider mounting locations and quantity
for complete safety
n Outside warning lights and horns
u Contact signal to DCS also common
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HVAC Systems
n One of the most expensive elements of a
shelter system
n Proper sizing requires calculation of the heat
loading
u Summation of the wattage of equipment inside
u Avoid maximum wattage vs normal operation
wattage
n Some analyzers (like GCs) make it easy to
capture hot air and vent outside
n A/C system may also provide the shelter
ventilation and purging
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Typical Ambient
Analyzer Rating:
14 °F to 122 °F

Shelter Utilities
Power
n Wattage and phase of power
n Breaker Boxes and Junction Boxes
u Sizing and location
n Separate conduit for power and
data signals
n UPS systems
n Shut off switches for each major
device
u Maintenance convenience
u Safety
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Instrument Air
n For analyzer operation like GCs
n For purging of analyzer electronics
n Confirm pressure requirements;
especially if vortex coolers are
involved
Plant Nitrogen
n May require oxygen deficiency
monitors
Steam / Water
Future expansion requirements

Header and Manifold Systems
n Simplifies plumbing throughout
the shelter
n Shared gas / utilities
u Air / Steam
u GC carrier gas
n Waste recovery headers
u GC vent gases (need to be atmospheric pressure)
u Check valves if tying into the process
(such as flare)
n Liquid recovery systems
u Storage tank
u Return pumps
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Analyzer Consumables
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n Consideration for space and plumbing
of analyzer consumables
u Some consumables need heating and
/ or pressurization
n GC’s and CEM systems in particular
have lots of consumables
u Carrier gas cylinders
u Calibration / validation gas cylinders
u Pure air or blanket gases

Data / Signal Wiring
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Data signal junction boxes
Separated from power conduits
(analog signals especially)
n Concern about power noise being
picked up by the analog lines
Ethernet connection
considerations
n Many analyzers now utilize Ethernet
n RJ-45 copper wiring vs fiber inside
shelter

Sample Conditioning Systems
Typically mounted outside
n Keeps bulk of process sample out of
shelter in case of a leak
n Opposite side of wall from analyzer
n Mounted chest level for easier
maintenance
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Cold climates may move SCS inside
n Perhaps split the shelter into
two zones
Heat tracing of
process lines
Don’t forget about …
Sample system signal
wiring between
analyzer and SCS

Proper Sample System Design is Critical
Key component of any extractive
analyzer
n Makes the sample compatible with
the analyzer
n Also handles calibration and
validation role
The best analyzer in the world will
give the wrong answer if the sample
is not correct
n Many users say 60 – 80% of the
problems with process analyzers is
due to the sample system
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Most installations require an
engineering review of the process
conditions for proper conditioning
n Every installation is different
n Engineering experience is key

Elements That Make Up A Complete Design
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CAT GASOLINE
1
1
2
3
4
5
6
7
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Sample Take-off Point / Sample Probe
Sample Preconditioning System
Transport Lines
Sample Conditioning System
Sample Return
Calibration / Validation
Atmospheric Vent
Safe Vent / Flare
2 4
3 3
7
8
6
8
3
5
D T / Lag Time Calculation
D
p

Examples Of Sample Systems
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Continuous Emissions Monitoring Systems (CEMS)
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Typical requirements
n NOx, SO2, CO, THC, HCl, O2, etc.
n Sample conditioning systems design is critical
n Tend to be General Purpose installations
Data Collection per regulatory
“Permission to Operate” Permit
n Hourly and daily averages
n Downtime and Excess Emissions
n Dedicated Data Acquisition system
Certification RATA and CGA tests
n Part of commissioning
n Done by independent auditor
n Quarterly and yearly checks to confirm
analyzer performance

Project Management Considerations
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Documentation
n Can be difficult to control due to wide diversity of
hardware suppliers
n Approval drawings
n When will “as built” documentation be available
Factory Acceptance Tests
n Analyzers at analyzer manufacturer vs inside shelter
Shipping
n Shelter crating (the forgotten cost)
n Shelters wider than 12’
n Overseas shipping
Typical Lead Times
n Engineering Design 4 – 6 weeks
n Simple Analyzers 6 – 8 weeks
n Yokogawa Gas Chromatograph 18 – 20 weeks.
n TDLR Analyzer House 10 – 12 weeks
n Analyzer House Integration 4 – 6 weeks

Shelter Purchase
Documentation
Project Mgmt.
FAT Inspections
Commissioning
Training
Spare Parts
Crating & Shipping
Analyzer System Integration – More Than It Seems
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More than simply getting a quote
and issuing a PO
n Complete and accurate specifications
Vendors prior experience with
system integration is key
n Especially with sample system design
Analyzer system integrators can
help with other project tasks
n Feed studies / writing specs
n Analyzer recommendations
n Start-up, Training, Spare Parts

Best Operation and Maintenance Practices
Analyzers and Analyzer Systems
are Repeatable
n To make an analyzer Accurate
we Calibrate
n DO NOT Over-Calibrate
Daily Visual PM will minimize
downtime
n Check SHS pressures, flows, &
temperatures
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Stock essential spare parts
n Consumables (filter elements,
pump kits, etc.)
n Major components (detectors,
spare columns, etc.)
Invest in Support:
n Start-up & Training
n Life Cycle (Maintenance)
Agreement (LCA)

Every Segment can affect Results!!!
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Shelter Safety
System

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Q&A
Select and send all questions to “Panelist” now so that
we can address these
Questions
If you have any questions for this Webinar topic, please
send them to webinars@us.yokogawa.com

Questions?
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Joe Goh
Analytical Product Manager
281-325-1871
Joe.Goh@yokogawa.com
Scott Eddleman
Analytical Technical Sales
936-520-1854
Scott.Eddleman@yokogawa.com
Nathan Bourque
Analytical Technical Sales
225-402-9550
Nathan.Bourque@yokogawa.com

The names of corporations, organizations, products and logos herein are either registered trademarks or
trademarks of Yokogawa Electric Corporation and their respective holders.
Thank you for attending
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Process Analyzer Sampling Systems Simplified

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