INSPECTION and TEST PROCEDURE GUIDELINES FOR ANALYZER SYSTEMS
- INSPECTION GOALS TO ASSURE:
- Fit for purpose and satisfaction of the client
- Applicable recognized engineering standard
- Quality Workmanship
- Compliance to schedule requirements
- QUALITY INSPECTION
- Inspection and test record sheet(s) to be completed for each Sample System, Preconditioning System, and/or Analyzer System
- PRE-TEST INSPECTION
- Inspect Quality of Workmanship. (Chipping, Paintwork, Neatness etc)
- Inspect to see that all ports are tagged correctly and they are installed straight.
- Inspect to see that the right tag material has been used (Engraved plastic’s “proper size and color required”, Stainless Steel, Formica etc.).
- Verify that the Sample Handling System(s) has been leak checked.
- Verify that all electrical equipment is tagged per drawings.
- Verify that correct fittings have been used per approved drawings.
- Verify that the wiring is correct and labelled per approved drawings.
- Verify that correct cable glands are fitted at each termination (if applicable).
- Check for loose fittings, screws, nuts, tubing, etc.
- Spot-check that tube/pipe is the correct size and is labelled correctly.
- Record all defects on inspection report and return for repair.
- Verify overall dimensions are per the approved drawings.
- Verify doors are located per approved drawings and door closures operate correctly. (if applicable)
- Inspect paint finish for scratches or chips.
- Verify all gland plates are in correct position.
- Verify safety glass or Plexiglas is fitted to all windows per the purchase order.
- Inspect to ensure that all equipment is in the correct location per the "As Built" drawings.
- Verify segregation of I.S. entries etc (if applicable).
- Inspect all pipe work and tubing runs to see that they meet the approved drawings.
- Inspect to see that all tube/pipe runs are secured and clamped where required.
- Verify grounding system is installed per the approved drawings.
- Verify all junction box terminals are labelled and all screws are tight.
- Re-check all items on defect sheets have been corrected.
- Record all defects.
- Each Sample Handling System and/or Analyzer System to be tested individually.
- The configuration for testing shall be with all electrical and pneumatic inputs connected where possible and the Analyzer control section connected or simulated to allow valve switching.
- The order of testing shall be as follows:
SYSTEM ACCEPTANCE AND TESTING PROCEDURES
This procedure shall prove the operational integrity of the complete system to ensure that the system will perform correctly when installed on site.
4.2 SCOPE OF TEST
The scope of this test procedure covers all Analyzer Systems and/or Sample Handling Systems.
4.3 APPLICABLE DOCUMENTS
All tests are to be performed using the relevant drawings and any discrepancies found shall be noted in red and an updated, “as built”, drawing shall be issued.
4.4 TESTING ORDER
i Visual inspection.
ii Electrical connections, if applicable.
iii Leak test.
iv Function test.
4.5 GENERAL TESTING PROCEDURE
All tests described hereafter shall be performed in accordance with safe working procedures.
4.6 DETAILED TEST PROCEDURE
4.6.1 Visual Inspection - Sample Systems
- Using the relevant documentation/drawings verify the presence of all items shown.
- Verify that all items are in the correct order and connected together in the order shown.
- Inspect equipment for damage.
- Inspect all tubing for neatness of installation, straightness and verify that it is securely held in position.
- Check approximately 10% of connections for correct usage of ferrules.
- Check materials used for tubing, valves, flow meters, relief valves, solenoids etc. is as per drawings and specifications.
4.6.2 Where electrical items are supplied, check:
- Correct voltage rating.
- Correct certification.
- Securely fixed.
- Wiring correct. (size, color, type)
- Terminal box covers accessible.
- Terminals tight.
- Cable dress correct.
4.6.3 Leak Test - Sample Systems
- The purpose of this test is to prove the gas integrity of the plumbing from the inlet connection through as much of the Sample Handling System as practicable.
- The method of testing will be by applying whichever the greater, 100-psi or process design pressure when connection will be directly made to process pipe work.
- The source of pressure will be a compressor with in-line filters or a compressed air cylinder.
- The leak test will be performed by blanking off all outlets from the Sample Handling System and pressurizing via the sample inlet to 100-psig or test pressure whichever the greater, then applying snoop indicator or equivalent to all joint fittings. Gauges, relief valves etc that would be over ranged by the test pressure shall be isolated and tested at 1.25 their normal operating pressure. Calibration vessels greater that 5 litre volume shall be hydraulically tested on a lock in and monitor pressure basis. Pressure should not drop more than 1% in 5 minutes.
- Adjust all flow meters while air is flowing through the system to ensure ball moves freely.
- If more than one sample stream, check each stream separately, opening valves/solenoid valves as required.
- Check operation of all relief valves by isolating that section of the Sample Handling System and applying pressure to the relief valve until it opens. Verify the pressure corresponds to specifications.
Care must be taken not to over pressurize any flow/pressure indicators or parts of the system not rated for the applied pressure, if the relief valve does not operate. Set relief valves at designated pressure.
- Repeat steps d. to f. with the system pressurized via each calibration line and the sample inlet blanked off, as applicable.
- Remove all blanks fitted to the system for testing and reconnect, as before, ensuring connections are tight.
- The leak test check for this sample system is now completed repeat the same steps for all Sample Handling Systems.
4.6.4 Electrical Distribution (if applicable).
It is assumed that all Analyzer control sections are connected as per the relevant drawings.
- Place all circuit breakers/switches to the OFF position.
- Perform insulation check on wiring.
- Connect input power to the supplier / client interface.
- Place main circuit breaker/isolator to the ON position, if supplied, and verify correct voltage to all users. Verify current ratings.
- If more than one supply, repeat above steps for all, and verify operation of end user.
- Check earth continuity and sizes.
- Check circuit breaker labelling.
5. VENTILATION / HVAC UNITS (if applicable).
This procedure outlines the steps undertaken to verify the correct operation of the equipment being supplied. The specific tests will depend upon the type of unit being supplied for each project. Consult the manual for functions to check. The following is a guide for systems having these features.
5.1 Ventilation / Steam heating
- Check primary and secondary fan function.
- While set to auto changeover, stop lead fan. Backup should start.
- Check any alarm functions.
- Run second fan in lead
- Repeat b & c.
- Run system on one fan.
- Check airflow alarms.
- Check operation of louvers.
- Close shelter doors; check that shelter positive pressure is as per specifications.
- Pressure test steam heating coil. (if applicable)
- Adjust thermostat until control valve is open.
- Immerse thermostat in warm water until valve closes.
- Operate unit at atmospheric pressure.
- At pressure input, increase pressure and monitor fan speed.
- Run unit at normal shelter pressure. If possible, pressurize shelter.
- Check operation of louvers.
- Activate gas input alarm. (if applicable)
- Monitor fan speed.
- Check any alarms.
- Adjust thermostat below ambient temperature.
- Check heating function.
- Adjust thermostat above ambient temperature.
- Check cooling function.
6. ANALYZER FUNCTION TEST PROCEDURES
- Inspection of Analyzers
6.1.1 Visual Inspection
- Documentation - Review calibration data sheets, manuals, and sales order drawing package for order compliance.
- Confirm outline and mounting drawings.
- Visually verify and check flow diagram vs. instrument.
- Confirm inspection requirements per order.
- Confirm model and serial number on each component.
6.1.2. Basic Operational Inspection
- All interconnecting wiring installed as per drawings including accessories, Utilities (power, air, carrier, and calibration gas) connected, and Analyzer powered up for operation. (If applicable).
- Check leak test documentation
- Verify system operation (sample inject, valve switching, (if applicable).
- Verify measured components of analysis are as per Data sheet.
- Check previously run stability records.
6.2 ANALYZER FUNCTION TEST PROCEDURES
Analyzer Quality Control sheet(s) in Section 7 to be completed for each Analyzer.
6.2.1 Analyzer verification
- Chromatographs will be run up on air and carrier gases.
- All operations will be proved.
- Baseline will be displayed to confirm response.
- Temperature control confirmed. (If applicable).
- Carrier flows checked as per data sheet. (If applicable).
- Vent and drain as per drawings.
- Analyzer will be pressure tested.
- Calibration gases shall be run.
- Outputs to be verified.
- Hazardous area certifications confirmed.
Communications will be verified between analyzer and highway/network related equipment. (If applicable)
Analyzer checks to be conducted according to operators manual.
6.2.3 Auxiliary components.
- Check alarm set points are per data sheet
- Check controller for diagnostic errors
- Apply appropriate test gas for each range
- Check local alarms per data sheet
- Check remote alarms contacts at terminal junction box
7.0 SUPPORTING DOCUMENTATION (click on the title to view the test records and tables)