1、 Design and installation of On-line analyser systems PUBLICATION 138 Edition 2 Released by IHS. NOT FOR RESALE ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION Design and installation of On-line analyser systems PUBLICATION 138 Edition 2 Copyright 2010 The Engineering Equipment and Materials Us
2、ers Association A company limited by guarantee. Registered in England. Company number 477838. ISBN 978 0 85931 174 8 Imprint reference 02-2010 Registered and Trading Address 10-12 Lovat Lane London EC3R 8DN Telephone: +44 (0)20 7621 0011 Fax: +44 (0)20 7621 0022 E-mail: saleseemua.org Website: www.e
3、emua.org EEMUA Publication 138 Design and installation of on-line analyser systems EEMUAii ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION The Engineering Equipment and Materials Users Association, more commonly known as EEMUA, is a European non-profit membership Association helping companies
4、that own or operate industrial facilities - the users of engineering equipment and materials. EEMUA aims to improve the safety, environmental and operating performance of industrial facilities in the most cost-effective way, thereby demonstrating and pursuing leadership in asset management. EEMUA Me
5、mbers pursue these aims through collaboration for mutual benefit, sharing engineering experiences and expertise and by promoting their distinct interests as the users of engineering products. Specifically, the aims of EEMUA Member companies are achieved by: providing the organisation within which ne
6、tworking, information sharing and collaboration on non-competitive technical matters can take place; influencing the way written regulations are interpreted and applied in practice; presenting and promoting Members views, and encouraging the application of good, sound engineering practices; developi
7、ng user guides, specifications, training and competency schemes; facilitating Members participation in national and international standards making; influencing relevant national and European legislation and regulations. Formed in 1949 as the Engineering Equipment Users Association, and re-named in 1
8、983 (as a result of taking over the materials association, OCMA), EEMUA has for more than fifty years given companies that own and operate process plants, power stations and other significant industrial facilities, a collaborative voice in addressing technical and engineering related issues that imp
9、act on good integrity management and asset management practices. The Association is open to companies of all sizes that meet its engineering user criteria. Further details of current Members of EEMUA is available on the Associations website, www.eemua.org. EEMUA activities often lead to the producti
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11、e Membership, write to enquirieseemua.org or call +44 (0)20 7621 0011. EEMUA Publication 138 Design and installation of on-line analyser systems EEMUAiii ABOUT THIS PUBLICATION Legal Aspects All rights, title and interest in this Publication belong to EEMUA. All rights are reserved. No part of this
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16、ed herein are based on the most authoritative information available at the time of writing and on current good engineering practice, but it is essential for the user to take account of pertinent subsequent developments and/or legislation. Any person who encounters an inaccuracy or ambiguity when mak
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18、 standard feedback form, a copy of which is provided towards the end of this Publication. An electronic version of the feedback form is available from EEMUA - e-mail your request for a copy to enquirieseemua.org, telephone your request to +44 (0)20 7621 0011, or download the form from the EEMUA webs
19、ite at www.eemua.org. Submit comments by e-mail (preferred) or post. Comments will be considered by the relevant EEMUA Technical Committees and may be incorporated in future editions of this Publication. New editions will be publicised on the EEMUA website. EEMUA Publication 138 Design and installat
20、ion of on-line analyser systems EEMUAiv EEMUA Publication 138 Design and installation of on-line analyser systems EEMUAv Contents Foreword . 1 1. General 3 1.1 Introduction . 3 1.2 Further Considerations . 3 1.3 Reliability 4 1.4 Design. 4 1.5 Centralisation . 4 1.6 Local Mounting . 4 1.7 Pre-Assemb
21、led Systems 4 2. Health, Safety and Environmental Considerations 7 2.1 Introduction . 7 2.2 Prevention of Explosions and Fires . 7 2.3 Prevention of Toxic and Asphyxiant Hazards 7 2.4 Radiation Hazards 8 2.5 Safety Facilities 8 2.6 Manual Shut-Down Facilities 8 2.7 Noise 8 3. Housings 9 3.1 Introduc
22、tion . 9 3.2 Definitions 9 3.2.1 Analyser Housing . 9 3.2.2 Analyser Case 9 3.2.3 Analyser Cabinet 10 3.2.4 Analyser Shelter. 10 3.2.5 Analyser House 10 3.3 Selection of Housing . 10 3.3.1 Analyser Case 10 3.3.2 Analyser Cabinet 10 3.3.3 Analyser Shelter 11 3.3.4 Analyser House 11 3.4 Area Classific
23、ation and Toxic Danger 11 3.4.1 Electrical Area Classification 11 3.4.2 Toxic and Asphyxiant Danger 11 3.5 Construction and Mounting . 12 3.5.1 General 12 3.5.2 Analyser Housings . 12 3.5.3 Analyser Houses 12 3.5.4 Analyser Shelters . 13 3.6 Analyser Housings with Natural Ventilation 13 3.6.1 Genera
24、l 13 3.6.2 Ventilation Requirements 13 3.6.3 Heating Requirements . 14 3.6.4 Analyser Shelters . 14 3.6.5 Analyser Cases 14 3.7 Analyser Housings with Forced Ventilation . 15 3.7.1 General 15 3.7.2 Ventilation Requirements 15 3.7.3 Air Intake System 15 3.7.4 Ventilation Fan Requirements 16 3.7.5 Air
25、 Flow Requirements 16 3.7.6 Heating Requirements . 16 3.7.7 Safety Monitors and Alarms . 17 EEMUA Publication 138 Design and installation of on-line analyser systems EEMUAvi 4. Sampling Systems . 21 4.1 Introduction . 21 4.2 Definitions 21 4.3 General Requirements 22 4.4 Sample Point Location 22 4.5
26、 Fast Circulating Systems (Fast Loops) 23 4.6 By-Pass Systems 24 4.7 Sample Recovery Systems 24 4.8 Special Considerations 25 4.9 Multi-Stream Systems 25 4.10 Construction . 26 4.10.1 General 26 4.10.2 Material Selection 27 4.10.3 Flushing Facilities 27 4.10.4 Blockage Removal 27 4.10.5 Heat Tracing
27、 and Insulation. 28 4.10.6 Minimising Risks from Leakage 28 4.10.7 Location of Equipment . 28 4.10.8 Instrumentation 29 4.10.9 Identification . 29 4.11 Effluent Disposal . 29 4.11.1 General 29 4.11.2 Vapour . 29 4.11.3 Liquid . 30 4.12 Calibration Facilities . 31 4.13 Automatic Calibration . 32 5. C
28、ommunications 33 5.1 Introduction . 33 5.2 Signal Transmission 33 5.3 Safety . 33 5.4 Cables . 34 5.5 Use of Signal . 34 5.6 Alarms 34 Appendix 1 Typical Analyser Sampling Probe 35 Appendix 2 Determination of Sample Probe Lengths . 36 A2.1 Introduction . 36 A2.2 Theory 36 A2.3 Calculations 36 A2.3.1
29、 Natural Frequency . 36 A2.3.2 Shed Frequency . 38 Appendix 3 Sample System Calculations . 39 A3.1 Lag Time and Pressure Drop in Sampling Lines 39 A3.1.1 Introduction 39 A3.1.2 Pressure Drop 39 A3.1.3 Flow Velocity . 39 A3.1.4 Lag Time/ Nomenclature . 39 A3.1.5 Graphical Solution . 40 A3.2 Component
30、 Equivalent Lengths and Pressure Drops . 41 A3.2.1 Introduction 41 A3.2.2 Equivalent Lengths 41 A3.2.3 Pressure Drop Allowances . 44 A3.2.4 Large Deviations in Friction Factor 45 A3.3 Examples of Sample System Calculations . 45 A3.3.1 Example 1 45 EEMUA Publication 138 Design and installation of on-
31、line analyser systems EEMUAvii A3.3.2 Example 2 49 Appendix 4 Natural Ventilation Calculations . 52 A4.1 Introduction . 52 A4.2 Ventilation Louvre Sizing 52 A4.2.1 Thermal Ventilation . 52 A4.2.2 Wind Ventilation 53 A4.3 Temperature Control 54 A4.3.1 House Without Additional Heating . 54 A4.3.2 Addi
32、tion of Heating with Fan Assistance 55 Appendix 5 Forced Ventilation Calculations . 57 Appendix 6 Analyser Houses with Forced Ventilation, Ventilation Failure and Flammable Gas Detection Trip Logic . 58 References 59 Figures Figure 1 Typical analyser sampling probe for line sizes NPS 2” and above 35
33、 Tables Table 1 Definitions related to sampling systems . 21 EEMUA Publication 138 Design and installation of on-line analyser systems EEMUAviii EEMUA Publication 138 Design and installation of on-line analyser systems EEMUA1 Foreword This publication provides guidance on the design and installation
34、 of on-line analyser systems. There are many International Standards and documents (referenced at the end) that relate to specific parts of the design and safety of on-line analyser systems. However, there is limited practical guidance available on the overall concepts, approaches, tools and methodo
35、logy for the design and installation of on-line analyser systems to ensure they perform with the required reliability and precision. This publication addresses these areas in five parts: 1. General 2. Health, Safety and Environmental Considerations 3. Housings 4. Sampling Systems 5. Analyser Communi
36、cations Whilst individual EEMUA member companies have varying practices for the design and installation of on-line analyser systems, the fundamental approach is generally similar. It is therefore hoped that this document will encourage standardisation within industry and lead to reduced design and c
37、onstruction costs, and improved safety. The word analyser has been used throughout this document to refer to instruments variously known as on-line analysers, process stream analysers, quality analysers, quality measuring instruments and process quality monitors. Where reference is made to Internati
38、onal Standards it should be noted that National Authorities may have statutory requirements that are mandatory. EEMUA Publication 138 Design and installation of on-line analyser systems EEMUA2 EEMUA Publication 138 Design and installation of on-line analyser systems EEMUA3 1. General 1.1 Introductio
39、n The chemical, food, petrochemical and pharmaceutical industries need to be able to control their processes to ensure safety and environmental compliance and to optimise operations for maximum profitability. The use of on-line process analysers is a valuable tool in helping to achieve these objecti
40、ves because analysers provide frequent (continuous or cyclic) analytical information on key process properties. This allows continuous on-line optimisation of the plant and rapid identification and correction of off-spec or undesirable operating conditions. Analyser repeatability is also usually bet
41、ter than the laboratory reference method as it allows closer control and targeting to product specification. The correct design and installation of on-line analysers are essential to achieve the full benefits from analyser systems. Analysers are expensive to install and maintain and should only be i
42、nstalled when there is a clearly defined and quantified benefit. On-line process analysers are usually justified for one or more of the following reasons: personnel and plant safety; pollution control, measurement and prevention; optimising plant operations for throughput and yield; control of final
43、 products as closely as possible to maintain specification and minimise product quality give-away; minimising product degradation and reprocessing costs in cases of plant upsets, change in mode of operation and start-ups; improving energy efficiency of boilers, distillation columns, furnaces and rea
44、ctors; and corrosion control. 1.2 Further Considerations The following considerations are also important in the application of on-line analyser systems. Analysers and associated sampling systems are often complex installations demanding attention from specialist personnel responsible for their maint
45、enance. Therefore, it is essential the end user has the appropriate, correctly trained manpower resources and spare parts available to ensure the analysers operate at the required level of performance to capture the anticipated benefits. The justification for analysers is not usually based on the re
46、duction in the cost of laboratory testing as this saving is often offset by the associated increase in analyser maintenance costs. To promote the effective use of analysers by operators it is often beneficial to discontinue the duplication of analyses by laboratory testing. Laboratory facilities are
47、 still required for validating and calibrating the on-line analyser systems and for any statutory requirements. Single stream analysers are preferred and are usually essential for continuous automatic control. EEMUA Publication 138 Design and installation of on-line analyser systems EEMUA4 On-line a
48、nalysers usually require environmental protection in the form of housings to ensure reliable operation. 1.3 Reliability The following points are important considerations in the design and installation of on-line analyser systems: correct location and orientation of sample point; proper design of the
49、 sample conditioning and sample transport systems; availability of clean and reliable utilities; environmental protection against corrosion, dust, heat/cold, humidity, rain and solar radiation; ease of accessibility for maintenance of all the analyser system components; proper design of calibration and validation facilities; and adequate preventive maintenance. 1.4 Design The design should permit adjustments, maintenance and repairs to be carried out quickly and preferably whilst the analyser is in
