Most new gas analyzer sampling systems are complicated and expensive—but increasingly necessary. Strict Bay Area Air Quality Management District (BAAQMD) regulations recently include updated fenceline monitoring requirements. While this can be done with old-fashion spot sampling, often it makes sense for Bay Area refineries to switch to a gas analyzer system because of the time lock requirements. 

Once they are installed, however, gas analyzer systems need a lot more calibration work than other sampling methods. Whether the gas analyzer calibration procedure is done at the grab sample panel, the analyzer, or somewhere in between, the most important element of getting a good representative sample over to the analyzer is the arrangement of tubing, panel and valve placement, and valve manifold design. 

Understanding the specific requirements of your process and unit space can help you achieve the most effective calibration system design. Of course, you might find the need to reach out for the help of a Design/Build partner. Here’s why.

Sampling System Design Goals and How to Meet Them

There are three main tasks gas analyzer sampling systems need to accomplish. Just as with any sample system, they need to take a good representative sample, transfer that sample to the analyzer, and support any analyzer calibration requirements. Let’s take a look at each one of these to understand how the design can give you an advantage. 

Taking a representative sample and getting it to the analyzer

Once a good sample point is identified, taking a representative sample is straightforward. But, depending on where the analyzer needs to be located, getting the sample to the analyzer can often take a sample pump to move enough sample volume quickly enough for a useful measurement. 

In some older Bay Area refineries, however, ensuring that all the required system components fit can be more than just a Health, Safety and Environment (HSE) challenge because of the space constraints in retrofitted units. Sometimes the analyzer must be placed far away from the sample point so you need a sample pump—and expert design assistance. To ensure that you have the right equipment installed correctly for taking a good representative sample, it makes sense to get a consultation with a Design/Build partner who can customize a solution. 

Supporting calibration requirements 

Planning for a system that supports gas analyzer calibration procedures is too often overlooked until late in the gas analyzer system design process. Modern gas analyzers typically require regular checks and calibration. Often check gasses from the cylinders may need to be run through an analyzer as frequently as once a day. Doing this requires a manifold that allows the sample point to be isolated and the check gas cylinder to provide gas to the analyzer. 

Similarly, monthly or quarterly analyzers typically require a calibration that is run on a range of gasses of known composition. Calibration manifolds for this procedure can be extensive.  The more complex your sampling system needs are, the more important it is to find design support. 

The Benefits of an Automated Gas Analyzer Calibration Procedure System 

Many calibrations can be automated so that daily checks and even the more extensive calibration runs can be automatically completed by the Distributed Control System (DCS). Implementing automation provides several convincing benefits, especially when you do a cost/ savings analysis. Let’s run through some of them.

• Significant time savings for operations and maintenance teams. When an analyzer’s measured value changes significantly, for instance, it can trigger alarms. If the DCS system knows it is performing a check or calibration, then it can also turn off those spurious alarms.
• Improved record keeping since the test records are automatically recorded in the DCS and thus available to any refinery personnel who need them. Typically, that means the Environmental Department can see that the required calibrations are complete in real-time. 
• Reduced field labor as valves are automatically opened and closed with the DCS recording testing results. This saves operational hours. 

While the extra automation can add to project costs, for compliance-critical gas analyzers, it can also deliver peace of mind to know that regulator required actions are indeed happening and being recorded automatically. But you should reach out to a sampling system vendor to understand the full range of options and the budgetary benefits of a new or updated system. 

The right sample station vendor for ensuring an effective gas analyzer calibration procedure should also be a solid Design/Build partner. Their expertise can help you get the right manifold to handle all of the calibration processes as well as automatic valves to simplify some of it.  

Choosing the Right Sample System Vendor is the Key

With a team of expert engineers and fabricators located right here in the California Bay Area, Swagelok is uniquely positioned to help with all your sampling needs. We can do an on-site visit to understand any space constraints then locally design and fabricate sampling systems and manifolds that meet your operational processes. As manifold and sample systems grow more complex and more common in Bay Area refineries, be assured that systems built by Swagelok are covered by the best Lifetime Warranty in the industry. 

 Swagelok Northern California can help with all of your sampling system and manifold needs from design through fabrication. Contact our team today by calling 510-933-6200.

Morgan Zealear | Product Engineer – Assembly Services

Morgan holds a B.S. in Mechanical Engineering from the University of California at Santa Barbara. He is certified in Section IX, Grab Sample Panel Configuration, and Mechanical Efficiency Program Specification (API 682). He is also well-versed in B31.3 Process Piping Code. Before joining Swagelok Northern California, he was a Manufacturing Engineer at Sierra Instruments, primarily focused on capillary thermal meters for the semiconductor industry (ASML).