RECOMMENDED PRACTICE

ISARP76.0.011998

Analyzer System Inspection and Acceptance

Approved 15 September 1998

TM

ISAThe Instrumentation, Systems, and Automation Society

ISARP76.0.011998, Analyzer System Inspection and Acceptance ISBN: 1-55617-680-5

Copyright 1998 by the Instrument Society of America. All rights reserved. Printed in the United States of America. No part of this publication 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 prior written permission of the publisher. ISA 67 Alexander Drive P.O. Box 12277 Research Triangle Park, North Carolina 27709

Preface

This preface, as well as all footnotes and annexes, is included for informational purposes only and is not part of ISA-RP76.0.01-1998. This recommended practice has been prepared as part of the service of ISA, the international society for measurement and control, toward a goal of uniformity in the field of instrumentation. To be of real value, this document should not be static, but should be subject to periodic review. Toward this end, the Society welcomes all comments and criticisms, and asks that they be addressed to the Secretary, Standards and Practices Board; ISA; 67 Alexander Drive; P. O. Box 12277; Research Triangle Park, NC 27709; Telephone (919) 549-8411; Fax (919) 549-8288; Email: standards@isa.org. The ISA Standards and Practices Department is aware of the growing need for attention to the metric system of units in general, and the International System of Units (SI) in particular, in the preparation of instrumentation standards, recommended practices, and technical reports. The Department is further aware of the benefits to USA users of ISA standards of incorporating suitable references to the SI (and the metric system) in their business and professional dealings with other countries. Toward this end, this Department will endeavor to introduce SI and acceptable metric units in all new and revised standards, recommended practices and technical reports to the extent possible. Standard for Use of the International System of Units (SI): The Modern Metric System , published by the American Society for Testing & Materials as IEEE/ ASTM SI 10-97, and future revisions, will be the reference guide for definitions, symbols, abbreviations, and conversion factors. It is the policy of ISA to encourage and welcome the participation of all concerned individuals and interests in the development of ISA standards. Participation in the ISA standards-making process by an individual in no way constitutes endorsement by the employer of that individual, of ISA, or of any of the standards, recommended practices, and technical reports that ISA develops. CAUTIONISA ADHERES TO THE POLICY OF THE AMERICAN NATIONAL STANDARDS INSTITUTE WITH REGARD TO PATENTS. IF ISA IS INFORMED OF AN EXISTING PATENT THAT IS REQUIRED FOR USE OF THE RECOMMENDED PRACTICE, IT WILL REQUIRE THE OWNER OF THE PATENT TO EITHER GRANT A ROYALTY-FREE LICENSE FOR USE OF THE PATENT BY USERS COMPLYING WITH THE RECOMMENDED PRACTICE OR A LICENSE ON REASONABLE TERMS AND CONDITIONS THAT ARE FREE FROM UNFAIR DISCRIMINATION. EVEN IF ISA IS UNAWARE OF ANY PATENT COVERING THIS RECOMMENDED PRACTICE, THE USER IS CAUTIONED THAT IMPLEMENTATION OF THE RECOMMENDED PRACTICE MAY REQUIRE USE OF TECHNIQUES, PROCESSES, OR MATERIALS COVERED BY PATENT RIGHTS. ISA TAKES NO POSITION ON THE EXISTENCE OR VALIDITY OF ANY PATENT RIGHTS THAT MAY BE INVOLVED IN IMPLEMENTING THE RECOMMENDED PRACTICE. ISA IS NOT RESPONSIBLE FOR IDENTIFYING
ISA-RP76.0.01-1998 3

ALL PATENTS THAT MAY REQUIRE A LICENSE BEFORE IMPLEMENTATION OF THE RECOMMENDED PRACTICE OR FOR INVESTIGATING THE VALIDITY OR SCOPE OF ANY PATENTS BROUGHT TO ITS ATTENTION. THE USER SHOULD CAREFULLY INVESTIGATE RELEVANT PATENTS BEFORE USING THE RECOMMENDED PRACTICE FOR THE USERS INTENDED APPLICATION. HOWEVER, ISA ASKS THAT ANYONE REVIEWING THIS RECOMMENDED PRACTICE WHO IS AWARE OF ANY PATENTS THAT MAY IMPACT IMPLEMENTATION OF THE RECOMMENDED PRACTICE NOTIFY THE ISA STANDARDS AND PRACTICES DEPARTMENT OF THE PATENT AND ITS OWNER. ADDITIONALLY, THE USE OF THIS RECOMMENDED PRACTICE MAY INVOLVE HAZARDOUS MATERIALS, OPERATIONS OR EQUIPMENT. THE RECOMMENDED PRACTICE CANNOT ANTICIPATE ALL POSSIBLE APPLICATIONS OR ADDRESS ALL POSSIBLE SAFETY ISSUES ASSOCIATED WITH USE IN HAZARDOUS CONDITIONS. THE USER OF THIS RECOMMENDED PRACTICE MUST EXERCISE SOUND PROFESSIONAL JUDGMENT CONCERNING ITS USE AND APPLICABILITY UNDER THE USERS PARTICULAR CIRCUMSTANCES. THE USER MUST ALSO CONSIDER THE APPLICABILITY OF ANY GOVERNMENTAL REGULATORY LIMITATIONS AND ESTABLISHED SAFETY AND HEALTH PRACTICES BEFORE IMPLEMENTING THIS RECOMMENDED PRACTICE.

The following people served as members of ISA Committee SP76: NAME D. Lewko, Chairman D. Rapley, Managing Director C. Ackerman B. Anderson *K. Anderson W. Bajek *J. Burkland S. Chappell *J. Converse *D. Coyle W. Dailey G. Erk C. Foresti M. Fraser P. Girling *R. Guillory J. Harman, III. G. Harms J. Hensel COMPANY Bantrel Inc. VECO Rapley Inc. Air Products & Chemicals Inc. Ashland Petroleum Company Technical Automation Services Corp. UOP Technical Automation Services Corp. National Institute of Standards & Technology Sterling Chemicals Inc. Applied Automation Inc. Process Analyzer Resources Inc. Consultant Tosco Refining Company Daniel Flow Products Inc. Mobil Technology Company Parsons SIP Inc. Beckman Instruments Inc. Hemlock Semiconductor Corp. Hach Company

ISA-RP76.0.01-1998

D. Hildebrand *F. Hormann A. Iverson K. Konrad M. Lanoue *K. LeBlanc *T. Lewis, Jr. C. Lucarino V. Madian *J. Mayfield J. McKinley D. Merriman E. Mooney R. Morris M. Murray *R. Muston *G. Nichols R. Ohlmeier F. Palacio D. Ross *J. Sablatura, Jr. D. Soleta R. Tarrant J. Tatera J. Thomason *H. Tummala J. Twork S. Ueda *P. VanVunren I. Verhappen M. Vickery *W. Wagner P. Wisneski, Jr. D. Wright *A. Yeager, Jr. F. Zikas *A. Znotins ________________________ *One vote per company

Vulcan Chemical Company Applied Automation Inc. Ivy Optiks Intek Corp. Delta F Corp. Exxon Chemical Company Applied Automation Inc. Anarad Inc. Imperial Oil Shell Oil Company Kin-Tek Labs Inc. MerTech Inc. Tytronics Inc. Flow Safe Sunoco Inc. Shell Chemical Company Sterling Chemicals Inc. Merrick & Company Analitec SL Camtec Environ. Consultants Exxon Research and Engineering Monsanto Company Nametre Company Dow Corning Company Omni Industrial Systems Inc. Parsons Tennessee Eastman Company Fuji Technosurvey Company Exxon Chemical Company Syncrude Canada Ltd. ARCO Chemical Union Carbide Corp. Chevron Research & Technology Company Microanalytics Instrument Corp. Union Carbide Corp. Parker Hannifin Corp. Shell Canada Ltd.

This recommended practice was approved for publication by the ISA Standards and Practices Board on September 15, 1998. NAME R. Webb, Vice President H. Baumann COMPANY Altran Corp. H. D. Baumann Inc.

ISA-RP76.0.01-1998

D. Bishop P. Brett W. Calder III M. Cohen H. Dammeyer W. Holland H. Hopkins A. Iverson K. Lindner V. Maggioli T. McAvinew A. McCauley, Jr. G. McFarland E. Montgomery D. Rapley R. Reimer J. Rennie W. Weidman J. Weiss J. Whetstone M. Widmeyer H. Wiegle C. Williams G. Wood M. Zielinski

Chevron Production Technology Company Honeywell Industrial Automation Controls Factory Mutual Research Corp. Flexonics Inc. The Ohio State University Southern Company Services Inc. Retired Ivy Optiks Endress + Hauser GmbH + Company Feltronics Corp. Instrumentation & Control Engineering LLC Chagrin Valley Controls Inc. Honeywell Industrial Automation & Controls Fluor Daniel Inc. VECO Rapley Inc. Rockwell Automation A-B Factory Mutual Research Corp. Parsons Power Group Inc. Electric Power Research Institute National Institute of Standards & Technology Carnegie-Mellon University Canus Corp. Eastman Kodak Company Graeme Wood Consulting FisherRosemount

ISA-RP76.0.01-1998

Contents

1 Purpose........................................................................................................................ 9 2 Scope .......................................................................................................................... 9 3 Analyzer inspection guidelines ................................................................................ 9 3.1 Safety and health considerations during testing...................................... 9 3.2 Documentation availability and applicability .......................................... 10 3.3 Maintainability ............................................................................................ 10 3.4 Interfacing compatibility of this system with external or connective devices..................................................................................... 10 3.5 Workmanship of tubing, wiring, conduit, supports, suitability for transportation to site, personnel safety hazards .................................... 10 3.6 Mutually agreed tests and proofing methods ......................................... 10 4 Checklists..................................................................................................................11

ISA-RP76.0.01-1998

1 Purpose

The purpose of this recommended practice is to establish procedures for analyzer, packaged analyzer system, and sample system inspection and testing. The guidelines are intended to provide minimum requirements for inspecting and testing analyzers, sample systems, and analyzer systems prior to final acceptance. In no instance is this recommended practice intended to override any established company procedures.

2 Scope

The attached inspection guidelines are recommended for use during structured analyzer system inspection. The inspection should be performed by qualified individuals. This recommended practice is intended to be a guide and not a "how to" document. These are guidelines and should be modified to include any special project requirements. These guidelines cover three basic areas, which are: a) ANALYZER INSPECTION: Inspection of an analyzer and the analyzer-specific application engineering. b) PACKAGED ANALYZER SYSTEM INSPECTION: Inspection of an analyzer building, shelter, enclosure, highway controllers, and any other equipment used to support the analyzer operation (other than the analyzer and its sample system). c) SAMPLE SYSTEM INSPECTION: Inspection of all vendor-supplied equipment that will be installed between the process sample tap and the analyzer. For the purposes of this document, STRUCTURED TESTING is defined as any witnessed test procedure that follows a predefined format.

3 Analyzer inspection guidelines

3.1 Safety and health considerations during testing

The test host (i.e., analyzer manufacturer or system integrator) should be responsible to ensure that the test site and all equipment meet all applicable electrical, safety and health requirements of the authority having jurisdiction.

ISA-RP76.0.01-1998

3.2 Documentation availability and applicability

All documentation should be system specific, and the latest revisions of the applicable documents should be used. Any documentation not pertinent to the project should be deleted (unless previously agreed to otherwise). All applicable documentation should be readily available at the time of the inspection. The documentation format should be as specified or agreed to beforehand (including language).

3.3 Maintainability
Wherever possible, all equipment should be installed in such a manner that any hardware items can be easily removed without the removal of any other hardware. Easy tool access to screws, nuts, fittings, etc. should be available. All equipment should be mounted so that removable covers are accessible and adequate clearance for removal is provided.

3.4 Interfacing compatibility of this system with external or connective devices

Analog and serial signals should be tested. Analog signals should be tested for linearity and ground isolation. If specified, all externally interfaced equipment should be provided (i.e., printers, recorders, plotters, protocol converters, etc.). All discrete outputs should be verified, as per the specification.

3.5 Workmanship of tubing, wiring, conduit, supports, suitability for transportation to site, personnel safety hazards
A small sample of tube fittings should be dismantled and checked for workmanship. All unfilled sealing fittings should be clearly identified with a red tag. Piping, wiring, and conduit should be sufficiently supported to withstand any anticipated vibration from site conditions or transportation. The inspector should check that there are no sharp edges, points or protrusions that could injure personnel during transportation, placement, or use.

3.6 Mutually agreed tests and proofing methods

The requirements for an inspection need to be agreed to early in the project (one of the purposes of this document). Vendor pre-inspection tests, the number of test and calibration samples, the proof of their content, and the duration of stability tests should be as specified and/or agreed to. Samples should contain all components of interest and all components that were identified on the application data sheet and that can interfere with this measurement. Whenever feasible, the customer should supply an acceptable analyzed standard for the inspection. Some portion of the stability test should be witnessed by the customer's representative. Test data should be presented in the specified or agreed-to format (e.g., raw data, summaries, statistical evaluations, or SPC charts). All outstanding action items should be resolved before the conclusion of the acceptance test. In the event that an open item cannot be resolved, an expected date should be identified by which the item will be resolved. An action log such as that at the end of Clause 4 is recommended for that purpose.

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ISA-RP76.0.01-1998

4 Checklists

The following may be used as inspection checklists or as references to help prepare checklists. It is suggested that any deviations from a checklist would be accepted only if agreed to in writing by both the customer and the vendor. Each type of analyzer system and/or sample can have unique requirements. Several blanks have been left in the following inspection guides, so users may easily incorporate additional items. Some of the listed items may not be relevant and may be deleted from a particular checklist; they are intended only as guides.

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11

ANALYZER INSPECTION GUIDE MANUFACTURER: PURCHASE ORDER: DATE: ANALYZER TAG NO.: MFG. ID#: SERIAL NO.:

PARAMETER 1 MECHANICAL Dimensions Mounting Weight 2 ELECTRICAL Volts Hertz Power (VA) 2.1 Effect of interruption 2.2 Insulation (Volts) Grounding R. F. shielding 2.3 Termination and wire labels 3 PIPING 3.1 Sample inlet 3.2 Sample return 3.3 Vent 3.4 Drain

SPECIFIED

WITNESS

COMMENT

V*

C*

V* = Vendor C* = Client

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ISA-RP76.0.01-1998

ANALYZER INSPECTION GUIDE MANUFACTURER: PURCHASE ORDER: DATE: ANALYZER TAG NO.: MFG. ID#: SERIAL NO.:

PARAMETER 3.5 Instrument air 3.6 Steam 3.7 Water 3.8 Reagent 3.9 Safety valve(s) 4 SAFETY Area classification Warning labels, signals, purge Personnel protection Certification Materials of construction exposed to the process 5 FUNCTION Zero Span 5.1 Calibration Number of points Certified samples Maximum deviation from curve (% of measured value) Response time rising

SPECIFIED

WITNESS

COMMENT

V*

C*

V* = Vendor C* = Client

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ANALYZER INSPECTION GUIDE MANUFACTURER: PURCHASE ORDER: DATE: ANALYZER TAG NO.: MFG. ID#: SERIAL NO.:

PARAMETER Response time falling Stability (hours) Repeatability Noise band (% full scale deviation) Standard deviation 5.2 Signals Output Fully floating? Linearity (# points) Minimum sensitivity Serial communications 5.3 Environment Effect of ambient temperature Effect of ambient pressure Materials of construction exposed to ambient atmosphere 6 DOCUMENTATION/ MANUALS

SPECIFIED

WITNESS

COMMENT

V*

C*

V* = Vendor C* = Client

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ISA-RP76.0.01-1998

ANALYZER INSPECTION GUIDE MANUFACTURER: PURCHASE ORDER: DATE: ANALYZER TAG NO.: MFG. ID#: SERIAL NO.:

PARAMETER 7 INDICATION

SPECIFIED

WITNESS

COMMENT

V*

C*

7.1 Local indicators 7.2 Local recorders

This system has been

Accepted By: Rejected By: Conditionally Accepted By:

V* = Vendor C* = Client

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SAMPLE SYSTEM INSPECTION GUIDE MANUFACTURER: PURCHASE ORDER: DATE: ANALYZER TAG NO.: MFG. ID#: SERIAL NO.:

PARAMETER 1 MECHANICAL Dimensions Enclosure 2 ELECTRICAL

SPECIFIED

WITNESS

COMMENT

V*

C*

3 PIPING/TUBING Material compatibility

4 SAFETY Area classification Warning labels, signals, certification Personnel safety Hydrostatic test(s) Gas leakage test Flow limiters

V* = Vendor C* = Client

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SAMPLE SYSTEM INSPECTION GUIDE MANUFACTURER: PURCHASE ORDER: DATE: ANALYZER TAG NO.: MFG. ID#: SERIAL NO.:

PARAMETER 5 ENVIRONMENT Effect of ambient temperature Effect of ambient pressure 6 DOCUMENTATION Identification tags/labels

SPECIFIED

WITNESS

COMMENT

V*

C*

7 COMPONENTS Filters Pressure gauges Flowmeters Relief valves Accessibility Maintainability Identification tags

V* = Vendor C* = Client

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SAMPLE SYSTEM INSPECTION GUIDE MANUFACTURER: PURCHASE ORDER: DATE: ANALYZER TAG NO.: MFG. ID#: SERIAL NO.:

PARAMETER 8 OVERALL TEST Sample loop(s) Sample conditioning system Stream selection Calibration system

SPECIFIED

WITNESS

COMMENT

V*

C*

All sample systems from entry of transport line should be tested at 1 - 1.5 times duty pressure.

This system has been Accepted By: Rejected By: Conditionally Accepted By:

V* = Vendor

C* = Client

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ISA-RP76.0.01-1998

PACKAGED ANALYZER SYSTEM INSPECTION GUIDE** MANUFACTURER: PURCHASE ORDER: DATE: ANALYZER TAG NO.: MFG. ID#: SERIAL NO.:

PARAMETER 1 MECHANICAL Dimensions & layout Mounting Weight

SPECIFIED

WITNESS

COMMENT

V*

C*

2 ELECTRICAL Area classification Certificate(s)

3 UTILITIES Steam Air Water Power circuit Lighting Vent header Drain header

** A separate Inspection Guide should be completed for each sample conditioning system or each analyzer.

V* = Vendor

C* = Client

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PACKAGED ANALYZER SYSTEM INSPECTION GUIDE MANUFACTURER: PURCHASE ORDER: DATE: ANALYZER TAG NO.: MFG. ID#: SERIAL NO.:

PARAMETER 4 SAFETY L.E.L. (Combustible) Oxygen deficiency Toxic Flow limiters Escape equipment Isolation valve(s)

SPECIFIED

WITNESS

COMMENT

V*

C*

5 OVERALL FUNCTION TEST

6 DOCUMENTATION

7 TAGGING

8 FAST LOOP AND SAMPLING SYSTEM

V* = Vendor C* = Client

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PACKAGED ANALYZER SYSTEM INSPECTION GUIDE MANUFACTURER: PURCHASE ORDER: DATE: ANALYZER TAG NO.: MFG. ID#: SERIAL NO.:

PARAMETER 9 COMMON SAMPLE RECOVERY SYSTEM

SPECIFIED

WITNESS

COMMENT

V*

C*

10 LEAKAGE TEST Utility header(s)

11 VENTILATION SYSTEM Ventilation Heater Air conditioner Temperature control Mechanical and finish inspection Control/alarm systems

This system has been

Accepted By: Rejected By: Conditionally Accepted By:

V* = Vendor C* = Client

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ACTION LOG MANUFACTURER: PURCHASE ORDER: DATE: ANALYZER TAG NO.: MFG. ID#: SERIAL NO.:

Item No.

Deviation

Corrective Action

Responsibility

Witness V* C*

V* = Vendor C* = Client

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ISA-RP76.0.01-1998

Developing and promulgating technically sound consensus standards, recommended practices, and technical reports is one of ISA's primary goals. To achieve this goal the Standards and Practices Department relies on the technical expertise and efforts of volunteer committee members, chairmen, and reviewers. ISA is an American National Standards Institute (ANSI) accredited organization. ISA administers United States Technical Advisory Groups (USTAGs) and provides secretariat support for International Electrotechnical Commission (IEC) and International Organization for Standardization (ISO) committees that develop process measurement and control standards. To obtain additional information on the Society's standards program, please write: ISA Attn: Standards Department 67 Alexander Drive P.O. Box 12277 Research Triangle Park, NC 27709

ISBN: 1-55617-680-5