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GIS 31-031 30 November 2006
GIS 31-031 30 November 2006
GIS 31-031
Applicability Group
Date DRAFT 30 November 2006
GIS 31-031
BP GROUP
ENGINEERING TECHNICAL PRACTICES
DRAFT 30 November 2006 GIS 31-031
Guidance on Practice for Continuous Emission Monitoring Systems (CEMS)
Foreword
This is the first issue of Engineering Technical Practice GIS 31-031. This Guidance on Industry Standard
(GIS) is a new document, not based on BP heritage documents.
Copyright 2006, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipient’s organization. None of the information
contained in this document shall be disclosed outside the recipient’s own organization
without the prior written permission of BP Group unless the terms of such agreement or
contract expressly allow.
Table of Contents
Foreword .............................................................................................................................................. 2
1. Scope of supply .......................................................................................................................... 4
2. Normative references ................................................................................................................. 5
3. Symbols and abbreviations ........................................................................................................ 5
4. Design and materials.................................................................................................................. 6
4.1. General............................................................................................................................ 6
4.2. Sample probe .................................................................................................................. 6
4.3. Materials .......................................................................................................................... 7
4.4. Sample conditioning system ........................................................................................... 8
4.5. Analysers....................................................................................................................... 10
4.6. CEMS analysers............................................................................................................ 11
4.7. Analyser controller/programmer ................................................................................... 11
4.8. Calibration/validation and carrier gas ........................................................................... 11
5. Inspection and testing and commissioning .............................................................................. 11
5.1. Data transmittal before factory acceptance test ........................................................... 11
5.2. Factory acceptance testing (FAT)................................................................................. 11
5.3. Site acceptance testing (SAT) ...................................................................................... 12
5.4. System start-up and commissioning............................................................................. 13
5.5. Spare parts .................................................................................................................... 13
6. Drawings and data.................................................................................................................... 13
7. Shipping and marking............................................................................................................... 15
8. Responsibility............................................................................................................................ 15
8.1. Analyser system ............................................................................................................ 15
8.2. Purchaser ...................................................................................................................... 16
Annex A (Informative) CEMS Data Sheet ......................................................................................... 17
Annex B (Normative) Data acquisition and control requirements ..................................................... 18
B.1 Introduction ............................................................................................................................... 18
B.2 DACS operator interface .......................................................................................................... 18
B.3 Analyser calibration .................................................................................................................. 19
B.4 Diagnostics ............................................................................................................................... 19
B.5 Printer ....................................................................................................................................... 20
B.6 Reports ..................................................................................................................................... 20
B.7 Marshalling ............................................................................................................................... 20
Annex C (Informative) Reference drawings ...................................................................................... 21
1. Scope of supply
2. Normative references
The following normative documents contain requirements that, through reference in this text,
constitute requirements of this technical practice. For dated references, subsequent amendments to, or
revisions of, any of these publications do not apply. However, parties to agreements based on this
technical practice are encouraged to investigate the possibility of applying the most recent editions of
the normative documents indicated below. For undated references, the latest edition of the normative
document referred to applies.
For the purposes of this GP, the following symbols and abbreviations apply:
I/O Input/output
An occupational exposure limit is the maximum average air concentration that most
workers can be exposed to for an 8 hour work day, 40 hour work week for a working
lifetime (40 years) without experiencing significant adverse health effects. A very small
percentage of individuals experience some discomfort or adverse health effects at or below
the exposure limit because of a wide variation in individual sensitivities or pre-existing
conditions. When employees work a shift longer than 8 hours per day, the exposure limit
must be adjusted (lowered) to prevent the employee from over exposure.
OSHA Occupational Safety and Health Administration
4.1. General
a. Exposed ferrous surfaces shall be galvanized or metalized.
b. The primer shall be chloride free if it is to be applied to stainless steel. Stainless steel
components shall not be painted unless specified.
c. Instruction shall be provided regarding where desiccant is to be included inside the
electronic component compartments and is not to be removed until start-up of the
instrument air purge.
d. Modules of the system shall be mounted so that any one module can be removed without
disturbing the remainder of the system.
e. Clearly labelled switches and valves to disconnect main power and shutoff incoming
utilities shall be locally mounted outside the shelter or local cabinet.
f. Common mode failure shall be considered. If shared sample pumps, coolers, PLCs, etc. are
used, redundancy may be necessary.
g. Space shall be allocated in the CEMS rack or shelter for the addition of future analysers/
equipment.
4.3. Materials
a. Components exposed to the process shall be resistant to the specified process fluid, i.e.
suitable for the line service classification of the process fluid being sampled. As a
minimum, materials in contact with hydrocarbon process fluids shall be 316 SS with Viton,
Teflon, Kalrez, or EPR gaskets and seals or other special materials as required by the
design of the system. For high temperature, Alloy 800 (common trade name Incolloy) shall
be used as required. No copper, zinc, or silver-bearing alloys are allowed in contact with
process streams. The use of Buna-N is not acceptable for use in CEMS.
b. Piping and tubing material shall be chemically resistant to the process and utility materials
being handled.
c. Piping and tubing shall be seamless. Tubing shall be degreased, washed, and dried.
Minimum pipe wall thickness for DN 15 – DN 40 (NPS ½ – NPS 1 ½) shall be Sch 80.
DN 50 (NPS 2) and larger shall be Sch 40. Wall thickness for tubing shall be 1,0 mm for
6 mm – 10 mm OD and 1,8 mm for 12 mm OD (0,035 in for ¼ in and 3/8 in OD and
0,065 in for ½ in OD). Preferred tubing for CEMS is Teflon.
d. Tubing fittings shall be compression type double ferrule fittings. Threaded connections in
tubing systems shall not be seal welded. Pipe and tube bends shall be used in place of
elbows, if possible. Centerline radius of pipe and tube bends shall be equal to 5 times the
nominal pipe diameter. Compression fittings in Teflon tubing shall use 316 SS sleeves
inside tubing to prevent crushing the tubing. Mixing of vendor fittings is not permitted
therefore consideration shall be given to current site preferred compression fitting vendor.
e. Low temperature melting alloys, except aluminium in cryogenic service, shall not be used
in line handling hydrocarbon or other flammable substances.
f. Copper or copper bearing alloys shall not be used in ammonia service or hydrocarbon
service.
g. Non-metallic materials shall not be used for hydrocarbon lines unless approved by BP.
h. Carbon steel shall not be considered for pipe subject to shock chilling if the fluid
temperature is below –45°C (–49°F).
i. Pipe threads shall be tapered and shall conform to ASME B1.20.1.
j. Soft sealed ball and plug valves shall not be used as block valves to the atmosphere.
k. Fittings and valves shall be forged or machined from bar stock.
l. To reduce the potential of leaks inside the shelter, the use of threaded or other connections
which can be disassembled shall be minimized inside the shelter.
m. Requirements for winterization and heat tracing shall be specified.
h. Sample filters with less that 10 microns shall include parallel filters and individual block
valves. Filter elements shall be removable without taking the filter body out of the sample
line. If possible, self-cleaning filters shall be used. Guard filtration shall be in the 0,5 to
1 micron range. The use of paper filters should be avoided.
i. The interconnection between components should be by tubing compression fittings.
j. Adequate facilities shall be provided to protect against unwanted backflow, overpressure,
or safety hazards.
k. Appropriate measures shall be taken to prevent plugging of sample lines due to freezing,
condensation, or build-up. Steam connections for steam out, back flush system, and/or
blowback systems shall be provided if plugging or build-up is likely to occur.
l. Pressure regulation shall be held to within 1% of set pressure over the ambient temperature
range.
m. Carrier gas flow rates shall be held to +/–½%.
n. Shop fabricator piping shall be cleaned in the shop before shipment. Other piping shall be
cleaned before operation of the equipment. Piping shall be cleaned by steam, air, water
flushing and, if necessary, by mechanical or chemical cleaning. Pipe headers shall slope to
a low point and include a drain or blowdown valve.
o. For toxic or flammable gas/ sample supply to the shelter or cabinet, a restrictor or
automatic cutoff shall be furnished between the supply regulator and the shelter or cabinet.
The restrictor capacity shall be less than 2 times normal flow rate. The cut-off shall
function on sudden increase of flow rate (such as would be caused by a line break). If the
sample is toxic/ asphixiant, flows should not allow any release inside the analyser shelter
to exceed the OEL of the toxic/ asphixiant gas present.
p. Sample transport tubing shall be supported by racks, ladders, or trays. The support design
shall take into account any thermal expansion and the need for covers for mechanical
protection. Sample transport tubing shall continuously slope either towards the sample tap
or towards the sample system.
q. Block valves shall be furnished as follows:
1. A primary block valve for isolating the sample installed outside the local cabinet or
shelter when the sample system components are mounted inside local cabinets or
shelter.
2. A block valve and a final sample flow meter or pressure indicator mounted inside the
shelter or cabinet close to the analyser.
r. Relief valves shall be provided downstream of pressure reducing valves if required to
protect the analyser and downstream conditioning system components.
s. Sample transport and conditioning system electrical components shall be approved for use
in the specified electrical area classification to a standard that is recognized by the
appropriate local authority. A label providing information on the approval shall be
permanently fastened to each component.
t. Teflon tape shall not be used as a pipe thread compound. Teflon paste may be used, but
local site practice shall prevail.
u. CEMS sample pumps and condensate pumps shall be mounted such that leaks will not
affect any electrical equipment and that either may be easily removed without disturbing
any other equipment.
v. The sample pump inlet vacuum gauge shall be mounted directly to the pump inlet to avoid
water condensation.
w. Remotely actuated valving shall be provided for an automatic calibration/ validation check
system which will introduce calibration/ validation gases into the sample probe. This
system shall also automatically control sample probe blowback operation.
x. For CEMS, an automatic check system shall operate on a timed basis. The time between
check cycles shall be adjustable by the user. There shall also be the capability for the user
to manually initiate a calibration/ validation check cycle. The validation cycle shall not
alter the calibration factors of the analysers in the system. While in validation or
calibration mode, separate volt free contacts shall operate to inform the site DCS system.
These signals are required to prove that the analyser has been calibrated/ validated
as required by the appropriate environmental agencies.
y. The following alarms shall be made available to the DACS, via volt free contacts, from the
sample handling system:
1. Cooler failure.
2. Moisture in sample.
3. Sample probe low temperature.
4. Sample low pressure/ flow.
5. Common fault.
6. Consideration should be given to a manual OOS switch.
Alarms a, b, and c shall automatically isolate the sample from the analysers.
4.5. Analysers
a. Analysers shall be as defined in the attached data sheets. Vendor shall be approved by BP.
b. Unless otherwise specified in the data sheet, each analyser shall have a continuous isolated,
linear 4 to 20 mA DC output signal in accordance with ISA S50.1. Independent zero and
span adjustments shall be provided.
c. Analytical equipment shall be provided which is suitable for installation in industrial
environments with each analysis unit independent of another so that a single failure does
not cause the loss of the other analysers. Each analyser shall be capable of removal without
affecting the remaining analysers.
d. Analysers shall operate on power supply as specified in the data sheet.
e. Whether the analyser output is self-powered or requires external power shall be stated.
f. In the event of a power source low voltage condition below the minimum required for
operation of any part of the analyser, that part shall perform an orderly shutdown.
g. Components shall be protected against RFI and EMI. This equipment shall not malfunction
in the presence of radio waves whether emitted on site, or offsite.
h. The operating and environmental limitations of analysers shall be clearly stated. If any
service factor (i.e. downtime) is required due to environmental effects, it shall be in the
quotation.
i. Flame type detectors shall have flame arrestors in the vent and local flame ignition switch.
j. A catalytic air clean-up unit shall be provided in the air supply of flame ionisation
detectors. Either a zero air generator or zero grade air shall be supplied for flame
photometric detectors.
k. Analysers shall be suitable for the electrical area classification. A label providing
information on the approvals or suitability for the area shall be provided on each enclosure.
d. Upon completion of fabrication and assembly, all systems shall be thoroughly tested
(including point wiring continuity check and piping/ tubing leak test), calibrated, and
functionally and analytically tested for twenty-four (24) hours as a system. This includes
performance runs with BP supplied samples if practical, with acceptance by BP. These
tests shall be completed before shipment to the job site.
e. Inspection and test shall be as follows:
1. Furnished items shall be checked against the final approved drawings.
2. Analyser components, tubing, sample systems, and utility piping shall be helium/
nitrogen leak tested with a bubble tester. Each system including analyser and any
system components supplied shall be pressurized to 1,5 times working pressure with
helium/ nitrogen. Maximum leakage through the bubbler shall be one bubble or less
in 60 seconds. If pressurized higher than 50 psig (345 kPag) with helium/ nitrogen,
the maximum permissible leakage rates are as follows:
a) Gas systems – 5 percent change per hour of the specified design pressure.
b) Liquid systems - No visible leakage.
f. Dimensions shall be checked against the final approved drawings.
g. The complete analyser system(s) shall be tested and set up to verify the correct functioning
of the supplied equipment using certified calibration samples. The test samples shall be at
the conditions and of the composition specified by BP. A minimum of two unique samples
shall be used for system checkout to prove linearity/ accuracy throughout the range of
expected results. A continuous operational test shall be conducted for each analyser for a
minimum of 24 hours. Recordings shall be submitted together with a copy of the test report
to BP for approval. Costs for the above operation tests shall be listed separately in the
quoted price. Data collected during the 24-hour operational test shall be subjected to
statistical analysis.
h. Alarms or alarm functions, safety systems, and other devices required by the Order shall be
demonstrated for proper function.
i. Full hook-up, functional test, and documentation of the local network including fiber-optic
and related communication package is required.
j. If the factory test is not run at the specified voltage and frequency, the suitability of the
equipment for the specified voltage and frequency shall be established by nameplate data
of equipment components or certified by the equipment components’ manufacturers.
k. Hydrostatic testing on pipe, excluding analyser piping and sample system piping, shall be
done as follows:
1. Piping shall be hydrostatically tested at 1 1/2 times the design pressure.
2. Piping systems in vacuum service shall be tested for full vacuum.
3. Austenitic stainless steel piping shall be tested and flushed with water having less
than 500 ppm (500 mg/L) chlorides. Potable water should meet this requirement. The
piping and tubing shall be drained immediately after flushing and dried by blowing
with clean filtered air.
l. Inspections and testing shall be documented in writing and submitted to BP for approval.
Shipment cannot be made without written approval from BP. Costs associated with
inspection and BP witness testing shall be included in the quoted price for the analyser
systems.
a. The cost of one set of manuals and certified “as-built” drawings for the supplied analysers
and analyser shelters shall be included in the quotation. Instructions and maintenance
manuals shall be provided for supplied equipment, including components used in the
sample transport and conditioning systems. Dimensional drawings shall be provided for
shelters, equipment racks, electrical equipment, and junction boxes. Plan drawings shall be
provided for equipment layout, sample and utility piping, and electrical. Interconnecting
cable schedules and wiring schematics for supplied power and signal wiring shall be
provided. The cost for additional copies of applicable documentation shall be quoted.
b. In addition to the information furnished in the quotation, any drawings or test data required
by BP for planning, layout, installation maintenance, and record purposes shall be
expeditiously submitted. The number of copies and the format shall be as specified in the
Purchase Order.
c. Drawings and data shall be identified with the project number, complete purchase order
number, client name, job location, item number, and service. Drawings and data sheets
shall include revision boxes to describe the latest revisions in full detail.
d. Certified “as built” drawings shall be furnished in the form specified on the Purchase
Order. The drawings shall show, as a minimum:
1. Dimensions.
2. The size, type, location, and identification of electrical field connections.
3. The size, type, location, and identification of utility connections.
4. Tubing/ piping diagrams for the complete system identifying connections with size
and rating. BP connections shall be clearly identified.
5. Wiring diagrams for the complete system identifying terminations. These drawings
shall include wiring type, size, and shielding: also these diagrams shall clearly
identify each connection to be made by BP.
e. The following engineering drawings and documents shall be submitted for approval:
1. Drawing index, shelter.
2. Substructure (skid) detail.
3. Door and wall panel location.
4. Front and left elevation.
5. Rear and right elevation.
6. Plan view, shelter.
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DRAFT 30 November 2006 GIS 31-031
Guidance on Practice for Continuous Emission Monitoring Systems (CEMS)
a. In advance of the shipment, a master shipping list listing total quantities of each section,
subassembly, or piece required for the complete shipment shall be furnished.
b. A packing list shall be included in each shipment which lists the contents by assembly
piece mark, individual instrument tag number and piece mark, or by item number of each
box, crate, bag, and skid. The list shall state whether the contents are complete or partial.
c. Shipments shall include: a copy of each instruction manual, drawings required for
assembly, installation, or erection, and one extra copy of data required. These documents
preferably shall be attached to the inside of the largest crate in the shipment and this crate
shall be marked accordingly. (Copies are independent of SDR.
d. Openings shall be plugged or blanketed to keep out foreign matter. Threaded connections
shall be fitted with a plug for the female end, and a thread protector for the male end.
e. The analyser and equipment shall be packaged properly for shipment. Shipment details
shall be supplied to BP.
8. Responsibility
8.2. Purchaser
a. Analyser data sheets with appropriate stream composition data and physical conditions will
be provided.
b. The utilities to the analyser shelter in the quantities and qualities stated will be provided.
c. The specification and design of components of the integrated system will be reviewed and
commented on by BP.
Annex A
(Informative)
CEMS Data Sheet
DS 31-031-
DRAFT 30 November 2006
Data Sheet for Continuous Emission Monitoring System (CEMS)
1 Facility Location:
2 Unit: 3 Project/Job No.:
4 Contractor: 5 PO No.: ______________ By Co.:
6 Detector Manufacturer: 7 Model No.:
8 Analyser Tag No.
9 Process Stream
Maximum Minimum Typical
10 Pressure Sample Source Point
11 kPag psig Sample Return Point
Conditions
Process
20
21
22
23
24
25
26
27
28
29
30
31
32 Analyser Digital Outputs Required Out of Service In Calibration In Validation
33 Analysis conformance to National codes
34 Analysis conformance to Local codes
35 Data Acquisition Required?
36 Analyser House Hazardous Area Classification
37 Analyser Power Supply V/Hz /
38 General Comments
39
40
41
42
43
44
45
46
47
48
NO DATE REVISION BY APP.
49
50
51
52
Annex B
(Normative)
Data acquisition and control requirements
Note: Most sites are using PI or some local custom software for
data management. This annex should be used only for sites
that do not have an existing data management system.
B.1 Introduction
a. Annex B defines the basic design and functionality for the DACS and the Operator
Interface Panel which is associated with each CEMS.
b. The DACS shall not only perform the basic analog and digital I/O functions, but shall also
establish the validity of data and pass these status flags to the plant DCS and/or plant wide
LAN. The interface to all systems shall be developed and coordinated.
c. The DACS equipment and programming shall provide 99% available operation.
Consideration shall be given to redundancy of certain major components such as power
supplies and data highway to maintain the integrity of the system.
d. The CEMS shall perform continuous calculations required and pass the data to the DCS
and/or LAN. Local calculations (within the CEMS) shall read all defined variables every
10 seconds and perform a rolling average, with the “minute” value or the “roll” being
identified as “MM:59”. This then becomes “clock” based minute value for subsequent
“rolling averages” for use by the report generating programs.
e. The DACS shall be modular in design and of open architecture to allow for future system
modification, upgrade, or expansion. Software versions used shall be defined and methods
for implementing new software releases shall be proposed.
f. Each CEMS shall have a dedicated DACS; however, the DACS shall include networking
capabilities that allow networking of the CEMS on a single LAN. Industry standard
protocols and serial interfaces such as Modbus, Ethernet, TCP/IP, etc., shall be considered
for the design.
g. The DACS design shall be implemented in a personal computer, PLC, or similar CPU
based system. System size shall include at least 30% spare memory and scan intervals shall
be no more than 1 second.
h. A block diagram shall be provided with the quotation which fully shows the design intent
of the integrated system including networking and expansion capabilities.
i. Final I/O list shall be generated during the design finalization and kick-off meeting.
The CEMS is under the direct control of the DACS. This includes both digital inputs
from sensors, digital outputs for device control, analog inputs from measurements,
and analogue outputs representing calculation results. The Operator Interface
provides the means for entering calibration constants, control, and readouts to be
conveniently entered or obtained.
a. The operator interface shall be located in the same shelter or cabinet as the CEMS.
b. The display shall show the name of the source measured by the CEMS. The interface shall
be password protected for secure access to the Main Menu.
c. The DACS shall have a Main Menu with the following options:
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DRAFT 30 November 2006 GIS 31-031
Guidance on Practice for Continuous Emission Monitoring Systems (CEMS)
1. Values – shall lead to menus that provide current real time readouts.
2. Reports – shall allow the subsequent menu items to be printed on the local printer.
3. Calibrations – shall provide for manual control, semi-automatic control, and the
setting of calibration constants.
4. Manual status – shall display the CEMS status.
B.4 Diagnostics
a. The DACS shall perform self diagnostics on subsystems. A “watch-dog timer” shall be
programmed to detect termination of I/O scanning or program malfunctions. Should the
“watch-dog timer” detect a fault, the DACS common trouble alarm shall be activated. The
“watch-dog timer” shall also monitor the data communications links and alarm on loss of
communications or “invalid data”.
b. In addition the DACS shall monitor the overall function of the sample handling system and
shelter or cabinet alarms. Sample System alarms monitored are described in clause 4.4.y.
Shelter/Cabinet low pressure alarm and HVAC failure alarm shall be monitored by the
DACS.
c. Alarms shall be stored within the DACS and also printed on a local printer.
B.5 Printer
A printer shall be provided and shall be located within the same shelter or cabinet as the CEMS.
The printer shall be laser jet, inkjet, or thermal printing type and be installed to conform to the
electrical area classification.
B.6 Reports
a. On demand, the DACS shall generate and send to the local printer the following reports:
1. Values of the measured and calculated variables at the time the report is requested.
2. Calibration Check report data from the last automatic or semi-automatic calibration
check.
3. Alarms report consisting of all the alarm status recorded in the DACS.
b. The DACS shall make available to the network raw data, rolling averages, calculated
values, and alarms.
c. An option shall be quoted for a historical storage system to be used in lieu of the local strip
chart recorder. Raw, calculated, and reported data shall be stored on this system. Storage
media shall be removable and transportable. A CD-ROM type system is preferred. The
system shall have the ability to store a minimum of one week of data and shall be designed
so that the storage media can be replaced without losing incoming data. File formats shall
be easily loaded onto commercially available software systems such as Excel, Word, or
Access. Date and time stamping shall be synchronized such that there is no apparent time
lag between the control system and the historical data. The ability to retrieve and review
the historical data from the DACS or other systems attached to the LAN shall be
considered in the design. Proposed system shall be completely described in the quotation.
B.7 Marshalling
a. Wiring of inputs and outputs to the DACS shall be via dedication marshalling. Interwiring
shall be supplied.
b. Marshalling shall include a minimum of 30% spare terminations.
c. Marshalling terminals shall be easily accessible and separate from other terminations in the
system.
Annex C
(Informative)
Reference drawings