GIS 31-031 30 November 2006

Document No.
GIS 31-031
Applicability Group
Date DRAFT 30 November 2006
Guidance on Industry Standard for

Continuous Emission Monitoring Systems
(CEMS)
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.
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The latest update of this document is located in the BP ETP and Projects Library
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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

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1. Scope of supply
a. The CEMS analyser shall be supplied in strict accordance with:

1. Attached data sheets.
2. This GIS.
3. Attached addendum.
b. If special features or improvements over this specification are required, these will be
specified on the instrument data sheets and shall be supplied.
c. Full responsibility shall be retained for designing, fabricating, or procuring the item or
items to perform in accordance with the specified operating and service conditions
specified in the instrument data sheets. Responsibility for complete compliance shall not be
relieved, in whole or in part, by anything contained in or omitted from this GIS.
d. Proposal shall be furnished with a bill of material describing in full detail each of the
devices supplied with the completed system.
e. The CEMS shall be fully certifiable under local, national, and international Environmental
Protection Agency regulations in force at the installation site.
f. As specified on the data sheets, a completely assembled physical structure with support
systems for the analysers, including sample systems, electricity for heat tracing sample
lines, and HVAC if specified shall be provided.
g. Inspection personnel shall communicate with the respective suppliers to assure that
components of the systems were received as required by the schedule and in operational
condition.
h. The location, installation, and provisions for maintenance requirements of each analyser
within the shelter or cabinet shall be coordinated. This shall include the coordination and
mounting of the analyser system components inside the analyser shelter. Space
considerations shall take into account front and back access to any panels, if required.
Sample transport system circulation loops, gas cylinders, permanently installed validation
sample cylinders shall not be located inside the shelter. Piping shall enter the shelter as
close as practical to the analyser so as to minimize the internal piping.
i. A written guarantee is required stating that full responsibility is assumed for the entire
analyser system and its installation if supervision of the field installation of the equipment
is provided. For CEMS systems, responsibility shall extend to include a guarantee that the
supplied system passes certification to the regulatory agency in jurisdiction of the
installation. Proposal shall state that any changes or modifications required to certify the
system shall be made.
j. Operating requirements of the system shall be stated. If the analyser system is mounted
inside a pressurized shelter or cabinet in a hazardous area, the system shall be designed to
remain in operation in the event of pressurization failure.
k. Components required for the sample systems, including sample probes, sample tubing,
insulation, and electrical tracing, as necessary, and sample conditioning hardware shall be
identified and quoted. The sample system shall be completely assembled and tested. Any
loose components shall be identified and kept to a minimum.
l. A comprehensive description of the equipment being quoted, including descriptive
bulletins of equipment proposed, shall be furnished. Information considered essential is a
descriptive drawing of the sample system proposed having components identified and
material of construction clearly stated. Brochures of major components, time of analysis (if

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applicable), description of any special features, reproducibility of analysis, and any

exceptions to this GIS shall be stated.
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.
American Society of Mechanical Engineers (ASME)

ASME B1.20.1 Pipe Threads, General Purpose (Inch).
Instrumentation, Systems, and Automation Society (ISA)

ISA S50.1 Compatibility of Analog Signals for Electronic Industrial Process
Instruments.
3. Symbols and abbreviations
For the purposes of this GP, the following symbols and abbreviations apply:
CD-ROM Compact disk read only memory
CEMS Continuous emission monitoring system
CGA Continuous gas analyser
CPU Central processing unit
DACS Data acquisition and control system
DCS Digital control system
EMI Electromagnetic interference
EPR Ethylene propylene rubber
FAT Factory acceptance test(ing)
HCD Hazard communication data
HCR Hazards communication rule
HVAC Heating, ventilating, and air conditioning
I/O Input/output
LAN Local area network
MSDS Material safety data sheet
NPS Nominal pipe size

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OEL Occupational Exposure Limit
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
OOS Out of service
P&I Process and instrument
PI Process information system
PLC Programmable logic controller
RFI Radio frequency interference
SAT Site acceptance test(ing)
SDR Supplier data requirements
TCP/IP Transport Control Protocol/ Internet Protocol
Basically, a suite of network protocols under the banner TCP/IP.
4. Design and materials
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.
4.2. Sample probe

a. Probe design shall be suitable for the functional and metallurgical requirements of the
application.
b. Insulation at the probe location shall be recommended as needed.
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c. Utilities required at the probe location shall be specified.

d. For stack mounted probes on CEMS applications the mounting flange shall be DN 100
PN 25 (NPS 4 Class 150) RF. A typical probe design is illustrated in Annex C; however,
this does not relieve responsibility for providing a suitable probe for the process.
e. CEMS sample/ filter probe design shall include a 0,5 micron filter. The sample/ filter
probe enclosure shall be heated to a minimum of 100°C (212°F) to prevent water vapour
condensation. If sulphurs are to be measured, this temperature should be held between
177°C and 204°C (350°F and 400°F). The enclosure shall be constructed of suitable
material so that sulphur compounds are not absorbed, but that it is resistant to chemical
degradation due to the sample, heated in parallel with filter, insulated, and suitably rated
for the area of installation. Facilities for ammonia removal and sample drying shall be
considered.
f. A suitable check valve shall be installed on the calibration line, immediately upstream of
the filter/ probe assembly to prevent backflow of sample gas into calibration gas lines.
g. A suitable check valve shall be installed on blowback lines immediately upstream of the
filter/ probe assembly to prevent sample gas ingress into purge lines.
h. The sample/ filter probe enclosure shall have a 12 mm OD x 1,5 m (½ in OD x 5 ft-0 in)
Hastelloy C sample tube attached to the connecting flange, which extend an appropriate
distance into the stack. The sample tube shall have a 45 degree miter, opening upward.
Wall thickness of tubing shall be specified.
i. The sample/ filter probe enclosures shall be certified for installation and operation in the
electrical area classification specified on the instrument data sheets.
j. A suitable temperature controller shall be provided to control the enclosure temperature.
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.
Note Sulphur compounds are absorbed into both stainless and

carbon steel.
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.

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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.
4.4. Sample conditioning system

a. If sample conditioning is required, a complete sample and conditioning system shall be
furnished to make the process sample compatible with the analyser and with the
application requirements by means of filtering, condensing, cooling, regulating pressure
and temperature, etc.
b. No part of the sample conditioning system shall be designed or fabricated by others.
Equipment necessary to condition the sample for the analyser based upon the sample tap
conditions specified on the data sheets shall be furnished. This may include (but not be
limited to) items such as pressure reducing valves, filters, strainers, coolers, heaters, flow
indicators, flow regulating valves, solenoids, vaporizers, pumps, etc., as required to
condition and regulate the sample. Model numbers for each component shall be listed on
the sample system drawing. The design shall be constructed with ease of maintenance in
mind along with reliability and simplicity of operation. A typical system for CEMS is
illustrated in Annex C.
c. The sample system shall be designed to condition and deliver representative samples with
a time lag not to exceed 60 seconds from sample tap through the analyser. The tubing size
and necessary components to meet these criteria shall be specified. Transport tubing
lengths greater then 300 ft (100 m) should be avoided.
d. Sample lines will be provided by others. Requirements for the sample line including heat
tracing, tubing size, maintained temperature, maximum temperature, tubing material,
number of tubes, and any other special requirements of the sample transport line shall be
clearly stated in the proposal.
e. CEMS sample systems shall be mounted inside of the analyser cabinet or analyser shelter.
Any high temperature piping shall be provided with guards for personnel protection.
f. A detailed P&I drawing of the proposed sample system which illustrates the entire system
from sample tap through the analyser to final sample disposal shall be provided.
Components and material shall be listed on the drawing. Exact manufacturer and model
numbers shall be listed on the drawing.
g. Sample vents and flame arrestors shall be provided. Analyser sample vents shall be piped
outside the cabinet or shelter. These vents shall be further piped to a freely ventilated point
more than 1,5 m (5 ft) above the enclosure or shelter and away from any fresh air intake.
Vent lines from analysers which may be subject to condensation shall be heat traced and
sloped to a low point drain. If back pressure is required necessary accessories to
accommodate this requirement shall be provided.
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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.

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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.

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4.6. CEMS analysers

CEMS analysers shall be specified as per the data sheet(s). They shall fully conform to site
local, national, and international codes of practice. Equipment supplied should also conform to
any standards required by local environmental regulatory bodies.
4.7. Analyser controller/programmer

a. The analyser controller or programmer shall be an integral unit with the analyser and shall
also be located inside the analyser shelter or cabinet. Electrical construction shall meet the
area classification stated on the data sheets.
b. The distance between the analyser controller and the analyser shall be determined by the
system layout. Interconnecting cables shall be supplied.
c. Loss of power to the programmer shall not cause loss of programmer memory.
d. Detector reading shall be automatically zeroed after each cycle for cyclic analysers.
e. Manual operation shall be available at the analyser.
f. Specific requirements for CEMS programmer and data systems (if required) shall be as
listed in Annex B.
4.8. Calibration/validation and carrier gas

a. Facilities required for calibration and carrier gas shall be supplied. A heated enclosure
shall be considered for calibration gases if gas stability is affected by environmental
conditions. Safety chains are required for securing cylinders.
b. Regulators for carrier and calibration gases shall be supplied. Interconnecting tubing from
the regulator to the sample system or analyser shall be supplied. Two stage regulators with
gauges and the CGA fittings shall be furnished for each cylinder. Manifolds shall also be
furnished to allow changing carrier gas bottles without shutting down the analyser system.
This system shall include required valves and inlet/ outlet pressure gauges, including
overpressure relief.
c. If a NOx converter is utilized within the measurement system then a calibration system
shall be provided to ensure the converter is working correctly.
5. Inspection and testing and commissioning
5.1. Data transmittal before factory acceptance test

Before factory acceptance test scheduling, chromatograms, digital photographs of equipment,
and other test data shall be submitted to BP for review.
5.2. Factory acceptance testing (FAT)

a. Complete and detailed inspection of materials, instruments, and components of the
analyser(s) shall be provided. BP will inspect and/or accept analysers before they are
shipped.
b. BP shall have the right to inspect equipment and system assemblies during the course of
fabrication at their discretion with a minimum of 24 hours notice. A representative shall be
available to accompany the BP representative for this purpose. The latest drawings and
bills of material of the items shall be available to BP at the time of inspection.
c. Six weeks before the FAT, detailed test procedures and complete functional checkout shall
be submitted for acceptance. Two weeks advance notice shall be given of the date and time
of the final inspection and test to be witnessed by BP. The analyser shall not be submitted
for final test until BP is notified in writing, that the analyser is fully operational.
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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.
5.3. Site acceptance testing (SAT)

BP will carry out witness testing after the system is installed at the jobsite.

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5.4. System start-up and commissioning

A Start-Up Service Proposal shall be provided which includes a competent Applications
Engineer for review of the installation, to supervise calibration and provide initial plant-site
start-up. Proposal shall state terms of this service. The person shall be competent, familiar with
project requirements, and experienced in trouble shooting, diagnosing the problems, and
bringing the analyser on line. In any case, the process analysers physical and performance
warranties shall be preserved for BP.
5.5. Spare parts

Proposal shall include lists of recommended spare parts for one year of operation, plus start-up/
commissioning spare parts. The start-up and one year spare parts shall be provided in two
separate lists.
6. Drawings and data
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.
Page 13 of 24
7. Floor plan, shelter interior.

8. Electrical arrangement diagram.
9. Tubing and piping arrangement diagram.
10. Power wiring schematic.
11. Interconnecting wiring diagram.
12. Interconnecting utilities diagram.
13. Sample conditioning systems, including sample line sizing and sample transport time
calculation.
14. Sample probe and probe subsystems.
f. Bill of materials, complete with manufacturer’s name, model number, and quantity shall be
supplied. Model number shall be complete so as to allow purchasing of exactly the same
replacement part.
g. Detailed (dimensional) drawings of process and utility bulkheads shall be submitted for
written approval by BP before construction.
h. For analysers containing radioactive sources, details of the source shall be forwarded to BP
within 4 weeks of order placement to allow site safety and local operating permits to be
obtained.
i. Preliminary documentation and software which is required to install and start-up the
integrated analyser system shall be shipped with the completed system.
j. The minimum quality and maximum pressure ratings for required utilities shall be
specified.
k. Additional documentation requirements shown in the [data document] shall be adhered to
in the analyser proposal.
l. If available, drawings and documentation shall be provided in software format such as
AutoCAD, Microsoft Office products (Word, Excel, etc.). The software package used shall
be specified. If applicable, the original media (diskettes, CD) containing the software
required to operate or interact with the system shall be provided.
m. MSDS is required for chemicals received at BP’s facilities. Equipment or materials
containing or coated with insulating oils, corrosion inhibitors, antifreeze solutions,
desiccants, or other chemicals or hydrocarbon substances shall be prominently tagged at
openings to indicate the nature of the contents, and precautions for shipping, storage, and
handling. A current MSDS for each substance shipped in or with the equipment that may
be regulated by the Federal OSHA’s HCR requirements shall be forwarded to the facility
before shipment. Copies of the MSDS shall be affixed in a protective envelope to the
outside of the shipment. The MSDS shall fully comply with Federal/ State OSHA HCD for
MSDS preparation, including a statement that the substance is considered hazardous under
HCR. Also, if any products are exempt from HCR, a statement to that effect shall be
included.
n. Delivery timing of the above documentation
1. At the quotation stage, the following, as a minimum, shall be supplied:
a) Technical response/ confirmation to each item in the specification.
b) Dimensional drawings and weights.
c) Hazardous area equipment certification.
d) Utility consumption details.
e) Spares schedule - Commissioning and 2 year operation, including special tools.
Page 14 of 24
f) A production bar chart identifying each activity duration, production milestones,

and any required freeze dates for receipt of final data from BP.
g) A typical Quality Plan for the equipment offered.
2. During the course of the project, comprehensive drawings and documentation shall be
provided. Sufficient drawings and documents shall be supplied to allow BP to provide
the following:
a) Electrical power supply requirements (including fusing).
b) Instrument signal requirements.
c) Piping and support of sample loops to/from the analyser.
d) Process and utility tie-in requirements.
e) Waste sample recovery requirements.
3. As a minimum, 3 copies of documentation shall be supplied for comment by BP
before manufacture, preferably on CD-ROM.
4. On completion of the analyser package and after final acceptance by BP, as a
minimum, 3 copies of documentation certified “As Built/ As Final” shall be supplied,
preferably on CD-ROM.
7. Shipping and marking
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
8.1. Analyser system

a. Design, construction, purchasing (as required), and testing of each analyser system and
analyser shelter shall be included. Materials and system design shall meet or exceed
specifications described in this document. Material selection and system design are subject
to BP acceptance. Analyser system shall comply with any local rules or regulations which
are specified by BP.
b. Although a typical sample system diagram is provided as reference in Annex C,
responsibility for the overall design of the system shall be retained.
c. Wiring and piping from the analyser system to well defined junctions outside the analyser
shelter shall be supplied. The analyser system shall include required sample conditioning
and handling equipment and peripherals described in this requisition and reference
documents.
Page 15 of 24
d. Sizing of fast loop sample line shall be included.

e. Technical assistance shall be made available during the guarantee period.
f. BP shall be informed of services, equipment, and utilities required at the analyser shelter.
BP shall be provided with drawings and documents required for connecting utilities and
sample lines to the analyser shelter.
g. On site training shall be provided, as required, by BP for the operation, maintenance, and
repair of equipment in the analyser system.
h. Test equipment, carrier gases and related equipment for the FAT shall be provided.
Required gases shall be specified at the time of initial offering.
i. A bi-weekly progress report shall be submitted on all phases of engineering including the
analyser delivery, drawing review, material purchases, construction, factory testing, on-site
installation, on-site testing and start up. BP shall be informed immediately of any delivery
slippage greater than one week.
j. Details of tie-down attachments, dimensions, and construction notes of foundation pads
shall be provided.
k. Any design acceptance by BP does not relieve responsibility to provide systems that
perform the required analysis.
l. Special tools and hardware for assembly shall be provided.
m. Any additional equipment required for the calibration, programming, and operation of the
analysers shall be recommended and quoted.
n. Proposal shall respond to each paragraph of this specification. Any exceptions taken shall
be noted on a paragraph by paragraph basis.
o. Quotation shall provide a complete list of utilities required, such as cooling water,
instrument air, steam, and electrical power. The list shall include quantities, flow rates,
pressures, voltages, and other defining parameters for the utilities to be supplied by BP,
including minimum quality and maximum pressure rating for required utilities. In addition,
consumables, such as calibration and carrier gases, and anticipated rates of consumption
for the analyser systems proposed, shall be identified and provided.
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.

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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
12 Temperature Sample Source Point

13 °C Sample Return Point
14 °F
Viscosity cS
15 Density kg/m3 lb/ft3
Component Output Range %
16
17
18
19
Sample Stream Analysis
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

Page 17 of 24
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.
B.2 DACS operator interface
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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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.3 Analyser calibration
a. Analyser calibration sequences shall be initiated either on demand (manual or semi-

automatically) or automatically for the CEMS. The automatic initiation shall occur as per
the local environmental regulatory body requirements.
b. DACS shall allow the system to be put in manual control and/or perform manual
calibration. These operations shall be performed through the DACS Calibration Menu. A
digital output shall be sent to the DCS and/or plant wide LAN that the system is “off line”.
If the system “off line” status remains on for more than one hour, the CEMS “common
trouble alarm” shall be activated.
c. The automatic calibration check sequence shall include the following:
1. NOx Analyser Zero and Full Scale Values.
2. CO Analyser Zero and Full Scale Values.
3. O2 Analyser Zero and Full Scale Values.
4. SO2 Analyser Zero and Full Scale Values.
5. NOx Analyser Zero and Upscale Check Values.
6. CO Analyser Zero and Upscale Check Values.
7. O2 Analyser Zero and Upscale Check Values.
8. SO2 Analyser Zero and Upscale Check Values.
9. Calibration Duration Time for Zero Gas.
10. Calibration Duration Time for Upscale Gas.
11. Calibration Initiation Time.
d. While the DACS is executing any manual or automatic calibration, the CEMS Status shall
be automatically changed to “In Calibration”. When automatic calibration is complete, the
CEMS Status shall be returned to “On Line” if the calibration check values are within the
required limits. If any check value drift is equal to or greater than 5,0% then the CEMS
Status shall be indicated as “Out of Control” and the CEMS Common Trouble Alarm shall
be initiated. Data substitution procedures shall be used during periods of “Out of Control”
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.

Page 19 of 24
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.

Page 20 of 24
Annex C
(Informative)
Reference drawings
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Document No.

Guidance on Industry Standard for

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a. The CEMS analyser shall be supplied in strict accordance with:

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applicable), description of any special features, reproducibility of analysis, and any

American Society of Mechanical Engineers (ASME)

Instrumentation, Systems, and Automation Society (ISA)

3. Symbols and abbreviations

CD-ROM Compact disk read only memory

CEMS Continuous emission monitoring system

CGA Continuous gas analyser

CPU Central processing unit

DACS Data acquisition and control system

DCS Digital control system

EMI Electromagnetic interference

EPR Ethylene propylene rubber

FAT Factory acceptance test(ing)

HCD Hazard communication data

HCR Hazards communication rule

HVAC Heating, ventilating, and air conditioning

LAN Local area network

MSDS Material safety data sheet

NPS Nominal pipe size

OEL Occupational Exposure Limit

OOS Out of service

P&I Process and instrument

PI Process information system

PLC Programmable logic controller

RFI Radio frequency interference

SAT Site acceptance test(ing)

SDR Supplier data requirements

TCP/IP Transport Control Protocol/ Internet Protocol

Basically, a suite of network protocols under the banner TCP/IP.

4. Design and materials

4.2. Sample probe

c. Utilities required at the probe location shall be specified.

Note Sulphur compounds are absorbed into both stainless and

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4.4. Sample conditioning system

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4.6. CEMS analysers

4.7. Analyser controller/programmer

4.8. Calibration/validation and carrier gas

5. Inspection and testing and commissioning

5.1. Data transmittal before factory acceptance test

5.2. Factory acceptance testing (FAT)

5.3. Site acceptance testing (SAT)

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5.4. System start-up and commissioning

5.5. Spare parts

6. Drawings and data

7. Floor plan, shelter interior.

f) A production bar chart identifying each activity duration, production milestones,

7. Shipping and marking

8.1. Analyser system

d. Sizing of fast loop sample line shall be included.

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12 Temperature Sample Source Point

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B.2 DACS operator interface

B.3 Analyser calibration