Real-time analyzers play an important role in many process manufacturing operations. Some examples include natural gas custody transfer, combustion efficiency monitoring, combustion emissions component analysis, flowing fluid compositional analysis and more.
Not only is the selection of the right analyzer for the right application important, but so is how it is installed and managed to assure accurate and reliable results over time. These complex analyzers often require proper sheltering as well as well-designed connections to the process and to the control system.
I caught up with Emerson’s Nouman Raja who shared with me the opening of a North American Analytical Systems integration facility in the Houston, Texas area. This facility, with 25,000-square foot (2320-sq. meters) of integration area, assists process manufacturers and producers in reducing costs and risks in executing complex analytical system projects.
These analytical systems are used across many industries including oil & gas production, gas processing, liquefied natural gas liquefaction and regassification, gas pipelines, power & energy production, refining and petrochemicals, chemicals, water & wastewater, and environmental/emissions monitoring.
Nouman described some of the types of systems integrated. These include Continuous Emissions Monitoring Systems (CEMS), liquid analysis systems, gas analysis systems and larger scale projects. Some liquid analysis systems include sample systems, stream & water analysis systems (SWAS), water quality systems (WQS) and liquid panels and racks for continuous online measurements for pH, ORP (oxidation-reduction potential), ozone, chlorine, dissolved oxygen, conductivity, silica and turbidity.
Examples of integrated gas analysis systems include analyzers with sample systems. These analyzers range from gas chromatographs (GC), continuous gas analyzers, combustion analyzers, and flame, gas and toxic detectors. Based on the area where these systems might be installed, they may be integrated into free-standing panels and racks, 3-sided shelters & open enclosures or other special requirements of the installation location.
Larger systems include fully integrated and environmentally controlled shelters with HVAC systems and highly customized shelters for difficult applications.
Nouman highlighted the comprehensive project approach to optimize project costs, reduce complexity and accommodate changes during the project. He noted the integrated project approach includes a dedicated project manager serving as a single point of contact throughout the project. During the early design phase, opportunities to standardize are sought to reduce customizations and their impacts on project schedule.
Project teams manage project through a secure project portal with advanced document management to help keep everyone on the project team advancing together. Some of the services performed through these projects include front end engineering and design (FEED), system design, manufacturing & execution, Emerson & 3rd party product procurement, certifications & documentation, factory acceptance testing (FAT), global logistics, site acceptance testing (SAT), startup & commissioning, training, and ongoing lifecycle services and support.
The Houston integration facility joins other full-scope design/build/integrate/project management integration facilities across the globe including Europe, South America, Asia, and the Middle East. The project teams at these facilities help make sure the analyzer applications perform as they are designed to improve safe, reliable and efficient operations.