Sentry Sampling Components

Steam and Water Sampling
Sentry Equipment Corp

Sampling Solutions Specialty Heat Exchangers
Sampling 101 and Sample System Components

Utility Market Components

Back Pressure/Relief Valve - BPRV
Sample Coolers Thermal Shut Off Valve TSV

Cation Resin Columns Variable Pressure Reducing Elements VREL
Steam and Water Sampling

Why sample? Monitor/adjust water chemistry to:
Maximize heat transfer efficiency Maximize time between chemical cleanings Maximize boiler life and turbine life Minimize operating & maintenance costs

Typical Plant Diagram

Typical Plant Diagram

Important Sample Conditioning Parameters The Primary objective of any sampling system is to transport and condition a sample without altering the characteristics of interest. The system parameters which need to be controlled are velocity, pressure and temperature.
Source: EPRI CS-5164, April 1987

Sample Point Selection, CC System

1. 2. 3. 4. 5. 6. 7. Gas Turbine Generators Steam Turbine Main Steam SiO2, Na, CC HRSG Boiler Drum - pH, SC, PO4, SiO2, Na, Chloride Condenser pH, SC, CC, Na, SiO2, DO Feed water SC, CC, Na, pH, SiO2 Boiler Feed Pump
Not shown:
Deaerator DO, pH, SC, CC
Economizer pH, CC
Sample Point Selection

Based on: System design Subject constituents Chemical treatment System specific problems

Sample Velocity
Velocity should be 5-6 ft/sec (1.8 m/sec) to maintain equilibrium of ionic and particulate components Ideally, sample lines in sample system should be 1/4 (6.35mm) tube; flow rate at of about 1200 cc/min and velocity at 6 fps (1.8 m/s).
Flow rate of 3300 cc/min in a 3/8 (9.5mm) tube with .065 (1.65mm) wall is 6 fps
Erosion/Deposition and Equilibrium

Velocity vs- Deposition

Deposition vs- Time

Sample Lag Time

Tube Size 1/4x.042 wall
Flow rate cc/min 500 1200
Velocity Ft/sec Lag Time/1000 2.5 6.5 min 6.0 2.8 min
0.9 2.2 3.0 6.0 18.7 min 7.6 min 5.6 min 2.8 min
3/8x.065wall
500 1200 1666 Theoretically correct > 3300 But not practical
1/2x.125 wall essentially equal to 3/8x.065 wall 6.0 ft/sec is approximately 1.8 m/sec

P&ID Complete System


Temperature Control Primary Coolers

Primary sample cooler approach temperature: 5 F (2.8 C) of coolant temperature Corrosion resistant tubing (18% Cr, 8% Ni), 316 SS, internal baffles Coil tubing to meet velocity requirements (1/4, 3/8 O.D.) (6.35mm, 9.5mm)
Sample Coolers

Sample Coolers

Sample Coolers
High Efficiency, Counter Flow Design All Stainless Steel Construction Single Gasket Design 100% Hydrostatic Testing, Tube and Shell Variety of Shell and Tube Materials Available

Sample Coolers - Materials

Standard Tubeside Materials:
316/316L Stainless Steel Alloy 625 (Inconel 625)
Standard Shellside Materials:


316/316L Stainless Steel 304 Stainless Steel 90/10 CuproNickel
Special Sample Coolers

Special sample coolers Cooling water with elevated chlorides and DO such as cooling tower water or potable water sources High temperature samples Use Inconel 625 coils, CuNi shells

Sample Coolers - Materials

Optional Tubeside Materials, short coil only:
Alloy C-276 (Hastelloy) Alloy 200 (Nickel) Alloy 400 (Monel) Titanium Zirconium 310SS
Optional Shellside Materials:
316/316L SS
Additional materials may be possible. Orbitally welded Sentry Equipment Corp long coils currently available in Zirconium
Sample Coolers

Competitive Products
Waters Equipment USA Dr Thedig - Germany Forbes Marshall India Lowe U.K. DKK Japan Nikkiso Japan/Taiwan Eurosysteme Watcom Westhoff

Analyzer manufacturers ABB Yokagawa Emerson Swan Others local

May not offer performance calculations Carbon steel shells Thin wall shells (drawn) May not offer dual baffle Tie-rod designs May offer dual-tube units which dont work for ASTM recommended flows

Important Sample Conditioning Parameters Secondary Cooling

Secondary cooling Recommended to control sample temperature to 77 F +/- 1 F (25 C +/- .5 C) Analyzer temperature correction algorithms should be evaluated for: Suitability given the expected sample matrix Sample temperature range Sensitivity Potential correction factor error

Isothermal Bath Coils in chilled water bath Chiller with hot gas bypass Thermal bypass valves Must have good mixing in bath Bypass valves can be problematic


Individual sample coolers Individual, high efficiency coolers for each sample stream Chilled water supply with hot gas bypass 75-76 F +/- 1 F (23.9 24.4 C) Hot gas bypass can add heat into system if samples are sub cooled

Field Study 19 Fossil and Nuclear plants 11 isothermal bath systems 8 individual cooler systems Isothermal baths averaged 77 F +/- 5 F ( 25 C +/- 2.7 C) Max deviation 28 F (15.6 C) Individual secondary coolers averaged 77 F +/2 F ( 25 C +/- 1 C) Max deviation 5 F (2.7 C)

Important Sample Conditioning Parameters

Pressure Reduction All Wetted Parts Stainless Steel Needle valves for 500 psig and less Rod-in-tube for pressures greater than 500 psig Drag valves and capillary tubes are prone to plugging Adjustable rod-in-tube preferable Cleanable in place Adjust to proper flow
Pressure Reduction
VREL (Variable Pressure Reducing Element)

VREL

VREL

Look alike or similar rod-in-tube designs may or may not operate well Capillary tubes - plug Drag valves plug - expensive Multiple needle valves wear same price as VREL


Important Sample Conditioning Parameters

Flow Control EPRI/ASTM recommends a Rod-in-tube pressure reducing device and backpressure valve combination Constant sample velocity/flow Reduced possibility of crud bursts Constant flow to on-line analyzers for repeatable analysis results BP/RV acts as a shock absorber
Back Pressure Regulator/Relief Valve

BP/RV
Assures Constant Pressure/Flow to Analyzers Protects System From Over Pressurization Large Orifice Wont Plug or Stick Constant Pressure Over Wide Flow Range Regulates to 20 psi (standard) Metallic Wetted Parts Stainless Steel Elastomer Viton Seat PEEK Optional pressure settings: 5 psig (0.3 barg), 7 psig (0.5
barg), 12 psig (0.8 barg), 28 psig (1.9 barg), 42 psig (2.9 barg), 60 psig (4.1 barg)
BP/RV

Back Pressure Regulator/Relief Valve

Tescom Go Coniflo Not designed specifically for the application


TSV
(Thermal Shut Off Valve)

Thermal Shut Off Valve (TSV)

Protects analyzer cells Protects operators Mechanically Actuated, Automatic Shut-Off for Thermal Protection Visual Trip Indication Optional Switch for Remote Indication Requires Manual Reset Latching Design No Pneumatic or Electrical Power Required

Wax valves automatically reset or are one use Sensor, controller and solenoid valve expensive problematic Bi-metal, mechanical or electro-mechanical trip point is not accurate, prone to failure

Thermal Shut Off Valve (TSV)

Standard Wetted Materials 316 Stainlesss Steel, Viton, PEEK Optional Elastomer Kalrez Standard Temperature Set Point = 120 F (49 C) Optional Temperature Set Points = 104 F (40 C), 140 F (60 C), 160 F (71 C), 153 F (67 C), 194 F (90 C), 203 F (95 C), 210 F (99 C)


Cation Resin Column

Cation Resin Column

Ion exchange resin uses porous beads that have a Hydrogen ion that can be exchanged for a cation. R = the resin and H = hydrogen ion 2R-H +Ca+2 <=> R2-Ca +2H+ The Resin column acts somewhat like a filter Reduces the masking effect of ammonia Proper length dia. Ratio for good ion exchange Prevents channeling Refillable

Cation Resin Column

Major Cations in water Ca+2 Mg+2 Na+ Fe+2 Cr+6 Ni+3 Cu+2 Zn+2 NH4+
Many, varied Resin is mostly the same but length to diameter ratio is key to proper ion exchange A larger column may offer more resin but poorer ion exchange Tubes are usually thinner, poor quality

ASTM Standards
ASTM 3370 Standard Practices for sampling water from
closed conduits
ASTM 5540 - Standard Practices for flow control and

temperature control for On-Line water sampling and analysis
Shortcut to ASTMD5540.pdf ASTM 1066 Standard practices for sampling steam Note: ASTM 1192 Similar to D5540 - suspended
Conclusion
A properly designed sample system transports and conditions samples from the point of extraction to analysis points without altering the characteristics of interest

End Of Sampling Components

Sample Line Fouling Solutions
Traditional sintered element filter, low temperature Strainer, high pressure and temperature Sentry Equipment Corp

Sludge trap Designed to drop out particles rather than trap them and hold them in the flow stream. Installed upstream of primary sample cooler Usually limited to boiler drum or similar samples Requires periodic flush to drain and piping to safe location (HP header, blow down tank)



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Steam and Water Sampling

Sentry Equipment Corp

Sampling 101 and Sample System Components

Sentry Equipment Corp

Utility Market Components

Sample Coolers Thermal Shut Off Valve TSV

Cation Resin Columns Variable Pressure Reducing Elements VREL

Steam and Water Sampling

Sentry Equipment Corp

Typical Plant Diagram

Sentry Equipment Corp

Typical Plant Diagram

Sentry Equipment Corp

Sentry Equipment Corp

Sample Point Selection, CC System

Sample Point Selection

Sentry Equipment Corp

Erosion/Deposition and Equilibrium

Sentry Equipment Corp

Velocity vs- Deposition

Sentry Equipment Corp

Deposition vs- Time

Sentry Equipment Corp

Sample Lag Time

Flow rate cc/min 500 1200

Sentry Equipment Corp

P&ID Complete System

Sentry Equipment Corp

Sentry Equipment Corp

Temperature Control Primary Coolers

Sentry Equipment Corp

Sentry Equipment Corp

Sentry Equipment Corp

Sample Coolers - Materials

Standard Shellside Materials:

Sentry Equipment Corp

316/316L Stainless Steel 304 Stainless Steel 90/10 CuproNickel

Special Sample Coolers

Sentry Equipment Corp

Sample Coolers - Materials

Optional Shellside Materials:

Sentry Equipment Corp

Sentry Equipment Corp

Sentry Equipment Corp

Sentry Equipment Corp

Important Sample Conditioning Parameters Secondary Cooling

Important Sample Conditioning Parameters Secondary Cooling

Sentry Equipment Corp

Important Sample Conditioning Parameters Secondary Cooling

Important Sample Conditioning Parameters Secondary Cooling

Sentry Equipment Corp

Important Sample Conditioning Parameters

Sentry Equipment Corp

Sentry Equipment Corp

Sentry Equipment Corp

Sentry Equipment Corp

Sentry Equipment Corp

Important Sample Conditioning Parameters

Back Pressure Regulator/Relief Valve