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ISA–RP

R E C O M M E N D E D P R A C T I C E

76.0.01–1998

Analyzer System Inspectionand Acceptance

d 15 September 1998

ISA–RP76.0.01–1998, 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 oth-erwise), without the prior written permission of the publisher.

ISA67 Alexander DriveP.O. Box 12277Research 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; E-mail: [email protected].

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.

CAUTION-

ISA ADHERES TO THE POLICY OF THE AMERICAN NATIONAL STANDARDSINSTITUTE WITH REGARD TO PATENTS. IF ISA IS INFORMED OF ANEXISTING PATENT THAT IS REQUIRED FOR USE OF THE RECOMMENDEDPRACTICE, IT WILL REQUIRE THE OWNER OF THE PATENT TO EITHERGRANT A ROYALTY-FREE LICENSE FOR USE OF THE PATENT BY USERSCOMPLYING WITH THE RECOMMENDED PRACTICE OR A LICENSE ONREASONABLE TERMS AND CONDITIONS THAT ARE FREE FROM UNFAIRDISCRIMINATION.

EVEN IF ISA IS UNAWARE OF ANY PATENT COVERING THISRECOMMENDED PRACTICE, THE USER IS CAUTIONED THATIMPLEMENTATION OF THE RECOMMENDED PRACTICE MAY REQUIRE USEOF TECHNIQUES, PROCESSES, OR MATERIALS COVERED BY PATENTRIGHTS. ISA TAKES NO POSITION ON THE EXISTENCE OR VALIDITY OFANY PATENT RIGHTS THAT MAY BE INVOLVED IN IMPLEMENTING THERECOMMENDED PRACTICE. ISA IS NOT RESPONSIBLE FOR IDENTIFYING

ISA-RP76.0.01-1998 3

ALL PATENTS THAT MAY REQUIRE A LICENSE BEFORE IMPLEMENTATIONOF THE RECOMMENDED PRACTICE OR FOR INVESTIGATING THEVALIDITY OR SCOPE OF ANY PATENTS BROUGHT TO ITS ATTENTION. THEUSER SHOULD CAREFULLY INVESTIGATE RELEVANT PATENTS BEFOREUSING THE RECOMMENDED PRACTICE FOR THE USER’S INTENDEDAPPLICATION.

HOWEVER, ISA ASKS THAT ANYONE REVIEWING THIS RECOMMENDEDPRACTICE WHO IS AWARE OF ANY PATENTS THAT MAY IMPACTIMPLEMENTATION OF THE RECOMMENDED PRACTICE NOTIFY THE ISASTANDARDS AND PRACTICES DEPARTMENT OF THE PATENT AND ITSOWNER.

ADDITIONALLY, THE USE OF THIS RECOMMENDED PRACTICE MAYINVOLVE HAZARDOUS MATERIALS, OPERATIONS OR EQUIPMENT. THERECOMMENDED PRACTICE CANNOT ANTICIPATE ALL POSSIBLEAPPLICATIONS OR ADDRESS ALL POSSIBLE SAFETY ISSUESASSOCIATED WITH USE IN HAZARDOUS CONDITIONS. THE USER OF THISRECOMMENDED PRACTICE MUST EXERCISE SOUND PROFESSIONALJUDGMENT CONCERNING ITS USE AND APPLICABILITY UNDER THEUSER’S PARTICULAR CIRCUMSTANCES. THE USER MUST ALSOCONSIDER THE APPLICABILITY OF ANY GOVERNMENTAL REGULATORYLIMITATIONS AND ESTABLISHED SAFETY AND HEALTH PRACTICESBEFORE IMPLEMENTING THIS RECOMMENDED PRACTICE.

The following people served as members of ISA Committee SP76:

NAME COMPANY

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

4 ISA-RP76.0.01-1998

D. Hildebrand Vulcan Chemical Company*F. Hormann Applied Automation Inc.A. Iverson Ivy OptiksK. Konrad Intek Corp. M. Lanoue Delta F Corp.*K. LeBlanc Exxon Chemical Company*T. Lewis, Jr. Applied Automation Inc.C. Lucarino Anarad Inc. V. Madian Imperial Oil*J. Mayfield Shell Oil CompanyJ. McKinley Kin-Tek Labs Inc.D. Merriman MerTech Inc.E. Mooney Tytronics Inc.R. Morris Flow SafeM. Murray Sunoco Inc.*R. Muston Shell Chemical Company*G. Nichols Sterling Chemicals Inc.R. Ohlmeier Merrick & CompanyF. Palacio Analitec SLD. Ross Camtec Environ. Consultants*J. Sablatura, Jr. Exxon Research and Engineering D. Soleta Monsanto CompanyR. Tarrant Nametre CompanyJ. Tatera Dow Corning CompanyJ. Thomason Omni Industrial Systems Inc.*H. Tummala Parsons J. Twork Tennessee Eastman CompanyS. Ueda Fuji Technosurvey Company*P. VanVunren Exxon Chemical Company I. Verhappen Syncrude Canada Ltd.M. Vickery ARCO Chemical*W. Wagner Union Carbide Corp.P. Wisneski, Jr. Chevron Research & Technology CompanyD. Wright Microanalytics Instrument Corp.*A. Yeager, Jr. Union Carbide Corp.F. Zikas Parker Hannifin Corp.*A. Znotins Shell Canada Ltd.

________________________

*One vote per company

This recommended practice was approved for publication by the ISA Standards and Practices Board on September 15, 1998.

NAME COMPANY

R. Webb, Vice President Altran Corp.H. Baumann H. D. Baumann Inc.

ISA-RP76.0.01-1998 5

D. Bishop Chevron Production Technology CompanyP. Brett Honeywell Industrial Automation ControlsW. Calder III Factory Mutual Research Corp.M. Cohen Flexonics Inc.H. Dammeyer The Ohio State University W. Holland Southern Company Services Inc.H. Hopkins RetiredA. Iverson Ivy OptiksK. Lindner Endress + Hauser GmbH + CompanyV. Maggioli Feltronics Corp.T. McAvinew Instrumentation & Control Engineering LLCA. McCauley, Jr. Chagrin Valley Controls Inc.G. McFarland Honeywell Industrial Automation & ControlsE. Montgomery Fluor Daniel Inc.D. Rapley VECO Rapley Inc.R. Reimer Rockwell Automation A-BJ. Rennie Factory Mutual Research Corp.W. Weidman Parsons Power Group Inc.J. Weiss Electric Power Research InstituteJ. Whetstone National Institute of Standards & TechnologyM. Widmeyer Carnegie-Mellon UniversityH. Wiegle Canus Corp.C. Williams Eastman Kodak CompanyG. Wood Graeme Wood ConsultingM. Zielinski Fisher•Rosemount

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Contents

1 Purpose ........................................................................................................................ 9

2 Scope .......................................................................................................................... 9

3 Analyzer inspection guidelines ................................................................................ 93.1 Safety and health considerations during testing ...................................... 93.2 Documentation availability and applicability .......................................... 103.3 Maintainability ............................................................................................ 103.4 Interfacing compatibility of this system with external or

connective devices ..................................................................................... 103.5 Workmanship of tubing, wiring, conduit, supports, suitability for

transportation to site, personnel safety hazards .................................... 103.6 Mutually agreed tests and proofing methods ......................................... 10

4 Checklists ..................................................................................................................11

ISA-RP76.0.01-1998 7

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 9

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 trans-portation 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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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.

ISA-RP76.0.01-1998 11

ANALYZER INSPECTION GUIDE

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

V* = Vendor C* = Client

PARAMETER SPECIFIED WITNESS V* C*

COMMENT

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

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COMMENT

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

ISA-RP76.0.01-1998 13





COMMENT

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

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This system has been Accepted By:

Rejected By:

Conditionally Accepted By:



COMMENT

7 INDICATION

7.1 Local indicators

7.2 Local recorders

ISA-RP76.0.01-1998 15

SAMPLE SYSTEM INSPECTION GUIDE




COMMENT

1 MECHANICAL Dimensions

Enclosure

2 ELECTRICAL

3 PIPING/TUBING Material compatibility

4 SAFETY Area classification

Warning labels, signals, certification Personnel safety

Hydrostatic test(s)

Gas leakage test

Flow limiters

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COMMENT

5 ENVIRONMENT Effect of ambient temperature Effect of ambient pressure

6 DOCUMENTATION Identification tags/labels

7 COMPONENTS Filters

Pressure gauges

Flowmeters

Relief valves

Accessibility

Maintainability

Identification tags

ISA-RP76.0.01-1998 17



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


Rejected By:




COMMENT

8 OVERALL TEST Sample loop(s)

Sample conditioning system

Stream selection

Calibration system

18 ISA-RP76.0.01-1998

PACKAGED ANALYZER SYSTEM INSPECTION GUIDE**


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



COMMENT

1 MECHANICAL Dimensions & layout

Mounting

Weight

2 ELECTRICAL Area classification

Certificate(s)

3 UTILITIES Steam

Air

Water

Power circuit

Lighting

Vent header

Drain header

ISA-RP76.0.01-1998 19

PACKAGED ANALYZER SYSTEM INSPECTION GUIDE




COMMENT

4 SAFETY L.E.L. (Combustible)

Oxygen deficiency

Toxic

Flow limiters

Escape equipment

Isolation valve(s)

5 OVERALL FUNCTION TEST

6 DOCUMENTATION

7 TAGGING

8 FAST LOOP AND SAMPLING SYSTEM

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PACKAGED ANALYZER SYSTEM INSPECTION GUIDE



Rejected By:




COMMENT

9 COMMON SAMPLE RECOVERY SYSTEM

10 LEAKAGE TEST Utility header(s)

11 VENTILATION SYSTEM

Ventilation

Heater

Air conditioner

Temperature control

Mechanical and finish inspection

Control/alarm systems

ISA-RP76.0.01-1998 21

ACTION LOG



Item No.

Deviation Corrective Action Responsibility Witness

V* C*

22 ISA-RP76.0.01-1998

80-5

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:

ISAAttn: Standards Department67 Alexander DriveP.O. Box 12277Research Triangle Park, NC 27709

ISBN: 1-55617-6

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