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Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Steam and Water SamplingSteam and Water Sampling
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
““Sampling 101” and Sample Sampling 101” and Sample System ComponentsSystem Components
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Utility Market ComponentsUtility Market Components
Thermal Thermal Shut Off Shut Off Valve - Valve - TSVTSV™™
Back Pressure/Relief Back Pressure/Relief Valve - BPRVValve - BPRV™™
Sample CoolersSample CoolersCation Resin Cation Resin
ColumnsColumns
Variable Pressure Variable Pressure Reducing ElementsReducing Elements
VRELVREL™™
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Steam and Water SamplingSteam 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
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Typical Plant DiagramTypical Plant Diagram
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Typical Plant DiagramTypical Plant Diagram
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Important Sample Conditioning Important Sample Conditioning ParametersParameters
““The Primary objective of any sampling The Primary objective of any sampling system is to transport and condition a system is to transport and condition a
sample without altering the sample without altering the characteristics of interest. The system characteristics of interest. The system parameters which need to be controlled parameters which need to be controlled are are velocityvelocity, , pressurepressure and and temperaturetemperature.”.”
Source: EPRI CS-5164, April 1987
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Sample Point Selection, CC Sample Point Selection, CC SystemSystem
1. Gas Turbine
2. Generators
3. Steam Turbine – Main Steam SiO2, Na, CC
4. HRSG – Boiler Drum - pH, SC, PO4, SiO2, Na, Chloride
5. Condenser – pH, SC, CC, Na, SiO2, DO
6. Feed water – SC, CC, Na, pH, SiO2
7. Boiler Feed Pump
Not shown:
Deaerator – DO, pH, SC, CC
Economizer – pH, CC
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Sample Point SelectionSample Point SelectionBased on:
System design Subject constituents Chemical treatment System specific problems
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Sample VelocitySample 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
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Erosion/Deposition and EquilibriumErosion/Deposition and Equilibrium
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Velocity –vs- DepositionVelocity –vs- Deposition
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Deposition –vs- TimeDeposition –vs- Time
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Sample Lag TimeSample Lag Time
Flow rate VelocityTube Size cc/min Ft/sec Lag Time/1000’1/4”x.042” wall 500 2.5 6.5 min
1200 6.0 2.8 min
3/8”x.065”wall 500 0.9 18.7 min1200 2.2 7.6 min1666 3.0 5.6 min
Theoretically correct > 3300 6.0 2.8 minBut not practical
1/2”x.125 wall essentially equal to 3/8”x.065 wall6.0 ft/sec is approximately 1.8 m/sec
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
P&ID – Complete SystemP&ID – Complete System
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Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Temperature Control – Primary Temperature Control – Primary CoolersCoolers
Primary sample cooler approach temperature: 5 ºF (2.8 ºC) 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)
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Sample CoolersSample Coolers
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Sample CoolersSample Coolers
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
• 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 CoolersSample Coolers
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Sample Coolers - MaterialsSample Coolers - Materials
• 316/316L Stainless Steel• Alloy 625 (Inconel 625)
Standard Tubeside Materials:Standard Tubeside Materials:
Standard Shellside Materials:Standard Shellside Materials: 316/316L Stainless Steel 304 Stainless Steel 90/10 CuproNickel
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• 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
Special Sample CoolersSpecial Sample Coolers
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Sample Coolers - Sample Coolers - MaterialsMaterials
• Alloy C-276 (Hastelloy)• Alloy 200 (Nickel)• Alloy 400 (Monel)• Titanium• Zirconium• 310SS
Optional Tubeside Materials, short coil only:Optional Tubeside Materials, short coil only:
Optional Shellside Materials:Optional Shellside Materials:
Additional materials may be possible.
Orbitally welded long coils currently available in Zirconium
316/316L SS316/316L SS
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Sample CoolersSample Coolers
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Competitive ProductsCompetitive Products• Waters Equipment – USA• Dr Thedig - Germany• Forbes Marshall – India• Lowe – U.K.• DKK – Japan• Nikkiso – Japan/Taiwan• Eurosysteme• Watcom• Westhoff
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Competitive ProductsCompetitive Products• Analyzer manufacturers
– ABB– Yokagawa– Emerson– Swan
• Others –local
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Competitive ProductsCompetitive Products
• 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 don’t
work for ASTM recommended flows
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Important Sample Conditioning Important Sample Conditioning Parameters – Secondary Parameters – Secondary
CoolingCoolingSecondary 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
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Important Sample Conditioning Important Sample Conditioning Parameters – Secondary Parameters – Secondary
CoolingCooling
Isothermal Bath– Coils in chilled water bath
Chiller with hot gas bypassThermal bypass valves
– Must have good mixing in bath– Bypass valves can be problematic
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Important Sample Conditioning Important Sample Conditioning Parameters – Secondary Parameters – Secondary
CoolingCooling
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
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Important Sample Conditioning Important Sample Conditioning Parameters – Secondary Parameters – Secondary
CoolingCoolingField 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)
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Important Sample Conditioning Important Sample Conditioning ParametersParameters
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
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Pressure ReductionPressure ReductionVRELVREL™™ (Variable Pressure Reducing Element) (Variable Pressure Reducing Element)
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
VRELVREL™™
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
VRELVREL™™
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Competitive ProductsCompetitive Products
• 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
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Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Important Sample Conditioning Important Sample Conditioning ParametersParameters
• 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”
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Back Pressure Regulator/Relief ValveBack Pressure Regulator/Relief Valve
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BP/RVBP/RV• Assures Constant Pressure/Flow to Analyzers• Protects System From Over Pressurization• Large Orifice Won’t 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)
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BP/RVBP/RV
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Back Pressure Regulator/Relief ValveBack Pressure Regulator/Relief Valve
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Competitive ProductsCompetitive Products
• Tescom• Go• Coniflo
– Not designed specifically for the application
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Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
TSVTSV(Thermal Shut Off Valve)(Thermal Shut Off Valve)
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Thermal Shut Off Valve Thermal Shut Off Valve (TSV)(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
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Competitive ProductsCompetitive Products
• 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
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Thermal Shut Off Valve Thermal Shut Off Valve (TSV)(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)
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Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Cation Resin ColumnCation Resin Column
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Cation Resin ColumnCation 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
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• Major Cations in water– Ca+2
– Mg+2
– Na+
– Fe+2
– Cr+6
– Ni+3
– Cu+2
– Zn+2
– NH4+
Cation Resin ColumnCation Resin Column
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Competitive ProductsCompetitive Products
• 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
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ASTM StandardsASTM 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.pdfASTM 1066 – Standard practices for sampling
steam
Note: ASTM 1192 – Similar to D5540 - suspended
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ConclusionConclusion
“ A properly designed sample system transports and conditions samples from the point of extraction to analysis points without altering the characteristics of interest”
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End Of Sampling End Of Sampling ComponentsComponents
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Sample Line Fouling SolutionsSample Line Fouling Solutions
Strainer, high Strainer, high pressure and pressure and temperaturetemperature
Traditional sintered Traditional sintered element filter, low element filter, low temperaturetemperature
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Sample Line Fouling SolutionsSample Line Fouling Solutions• 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)
Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers
Sample Line Fouling SolutionsSample Line Fouling Solutions