SENTRY EQUIPMENT CORP The Sampling Connection Corrosion Products Sampler (CPS)
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SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
Corrosion Products Sampler (CPS)Corrosion Products Sampler (CPS)
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
New CPS FeaturesNew CPS Features New flow meter & totalizerNew flow meter & totalizer AC connection standardAC connection standard
90-264Vac 47-63Hz input90-264Vac 47-63Hz input Battery option availableBattery option available
Battery indication meterBattery indication meter Average 3 month runtime Average 3 month runtime
between chargesbetween charges 24-48 hr recharge time24-48 hr recharge time
Total volume is customer resettableTotal volume is customer resettable Flow rate can also be displayed Flow rate can also be displayed
(mL/min)(mL/min)
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
Corrosion Products Sampler (CPS)Corrosion Products Sampler (CPS)
Collects a sample of dissolved and particulate Collects a sample of dissolved and particulate materialsmaterials
Totalizes sample flowTotalizes sample flow ASTM D6301-98ASTM D6301-98 Corrosion studies and pseudo on-line Corrosion studies and pseudo on-line
corrosion analysiscorrosion analysis Boiler tubes, pre-heaters, condenserBoiler tubes, pre-heaters, condenser
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
CPS Flow DiagramCPS Flow Diagram
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
CPS BenefitsCPS Benefits
Identify corrosion productsIdentify corrosion productsCollects particulates for metals analysis - Fe, CuCollects particulates for metals analysis - Fe, CuUse anion and cation filters for dissolved metalsUse anion and cation filters for dissolved metals
Locate source of corrosionLocate source of corrosion Quantify rate of corrosionQuantify rate of corrosion Measure effectiveness of treatmentMeasure effectiveness of treatment Locate areas of corrosion product accumulationLocate areas of corrosion product accumulation
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
Major ComponentsMajor Components High pressure filter holderHigh pressure filter holder Totalizing meter for high accuracy/low flow Totalizing meter for high accuracy/low flow
ratesrates Flow control circuitFlow control circuit Optional bypass circuitOptional bypass circuit Optional sample cooler (Above 55C)Optional sample cooler (Above 55C) Optional battery packOptional battery pack
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
Sample Point SelectionSample Point Selection
Based on:Based on:System designSystem designSubject constituentsSubject constituents Chemical treatmentChemical treatment System specific problemsSystem specific problems
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
CorrosionCorrosion
Corrosion affects:Corrosion affects: Equipment reliabilityEquipment reliability Plant safetyPlant safety Efficiency and capacityEfficiency and capacity
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
CorrosionCorrosion
Specifically:Specifically: Material degeneration at point of attackMaterial degeneration at point of attack Migration through the systemMigration through the system
Collection on turbine bladesCollection on turbine blades Collection on heat transfer surfacesCollection on heat transfer surfaces Accumulation at various points leading to Accumulation at various points leading to
additional corrosionadditional corrosion
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
Why Sample?Why Sample?
Improve plant safety & equipment Improve plant safety & equipment reliabilityreliability
Increase plant efficiency and capacityIncrease plant efficiency and capacity Reduce frequency between routine Reduce frequency between routine
cleanings of plant heat exchanger cleanings of plant heat exchanger equipmentequipment
Reduce plant operating costs Reduce plant operating costs
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
Why Sample?Why Sample?
Use sample data to:Use sample data to: Make adjustments in treatmentMake adjustments in treatment Make adjustments in lay up proceduresMake adjustments in lay up procedures Schedule maintenanceSchedule maintenance
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
Why Sample?Why Sample?
Locate the sources of corrosion productsLocate the sources of corrosion products Economizer, Condenser, etc.Economizer, Condenser, etc.
Determine the rate of corrosionDetermine the rate of corrosion Historical base, startup deviations, treatment changesHistorical base, startup deviations, treatment changes
Identify the type and cause of the corrosionIdentify the type and cause of the corrosion Type of materialType of material
Track the path of corrosion productsTrack the path of corrosion products Collection, settling, material removalCollection, settling, material removal
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
Typical Sampling PointsTypical Sampling Points
HotwellHotwell Monitor starting concentrations.Monitor starting concentrations.
DA OutletDA Outlet Monitor quality of feedwater indicating problems Monitor quality of feedwater indicating problems
with feedwater system components.with feedwater system components. Economizer Inlet Economizer Inlet
Quality of feedwater entering the boilerQuality of feedwater entering the boiler Steam Steam
Quality of steam to turbineQuality of steam to turbine
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
Proper Corrosion Products Proper Corrosion Products Sampling TechniqueSampling Technique
Isokinetic Sampling Isokinetic Sampling Sample velocity entering sample port is same as sample streamSample velocity entering sample port is same as sample stream
Sample Flow rateSample Flow rate– Constant, continuousConstant, continuous– New lines should be “seasoned”New lines should be “seasoned”
Location Location – As close as possible to the sourceAs close as possible to the source
Fittings/BendsFittings/Bends– MinimizeMinimize
Tube DiametersTube Diameters– Select to provide 6 ft/sec velocity for waterSelect to provide 6 ft/sec velocity for water
Sample Tube CompatibilitySample Tube Compatibility Refer to ASTM Method D1192, D1066Refer to ASTM Method D1192, D1066
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
Proper Corrosion Products Proper Corrosion Products Sampling TechniqueSampling Technique
Grab samples are not enough!Grab samples are not enough! Corrosion is dynamic and does not Corrosion is dynamic and does not
follow a regular patternfollow a regular pattern Transport is not uniformTransport is not uniform
Varies with flow ratesVaries with flow rates Crud burstsCrud bursts
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
Proper Corrosion Products Proper Corrosion Products Sampling TechniqueSampling Technique
A better alternative to grab sampling: An A better alternative to grab sampling: An integrated sampleintegrated sample A measured flow through a filter for a A measured flow through a filter for a
significant period of timesignificant period of time Collect insoluble and soluble productsCollect insoluble and soluble products
.45 micron filter.45 micron filter Ion exchange filtersIon exchange filters
Measure total flowMeasure total flow
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
Proper Corrosion Products Proper Corrosion Products Sampling TechniqueSampling Technique
Analyze filtered productsAnalyze filtered products Acid digestion + atomic absorptionAcid digestion + atomic absorption X-ray fluorescenceX-ray fluorescence
Calculate average concentrationsCalculate average concentrations
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
Corrosion Products Sampler Corrosion Products Sampler Design CriteriaDesign Criteria
Inlet Isolation ValveInlet Isolation Valve Sample CoolerSample Cooler Bypass Flow StreamBypass Flow Stream Filter Isolation ValveFilter Isolation Valve Filter PurgeFilter Purge Filter HolderFilter Holder Flow Control CircuitFlow Control Circuit
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
Inlet Isolation ValveInlet Isolation Valve
Designed to minimize corrosion product Designed to minimize corrosion product buildup, ball or plug type if possible.buildup, ball or plug type if possible.
Valve packing, stem and tip selected for Valve packing, stem and tip selected for the applicationthe application
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
Sample CoolerSample Cooler
Must be capable of reducing the sample Must be capable of reducing the sample inlet temperature to below 122 F (50 C) inlet temperature to below 122 F (50 C) with the correct sample line velocitywith the correct sample line velocity
Sample to be cooled using a single Sample to be cooled using a single stage cooler having no internal weld stage cooler having no internal weld joints on the tube sidejoints on the tube side
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
Bypass Flow StreamBypass Flow Stream
Used to establish the correct sample Used to establish the correct sample line velocityline velocity
Helps to reduce and/or eliminate the Helps to reduce and/or eliminate the effects caused by starting and stopping effects caused by starting and stopping of sample flows through the sample of sample flows through the sample filter assembly during routine changing filter assembly during routine changing of the filter paperof the filter paper
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
Filter Isolation ValveFilter Isolation Valve
Isolates the filter holder during Isolates the filter holder during assembly and disassemblyassembly and disassembly
The valve should be a ball or plug typeThe valve should be a ball or plug type
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
Filter PurgeFilter Purge
Used to purge the filter holder assembly Used to purge the filter holder assembly between corrosion product collectionsbetween corrosion product collections
Eliminates cross contamination Eliminates cross contamination between samplesbetween samples
Removes corrosion particulate that may Removes corrosion particulate that may have been released because of have been released because of mechanical vibration during filter mechanical vibration during filter disassemblydisassembly
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
High Pressure Filter HolderHigh Pressure Filter Holder
Designed to house up to one particulate filter Designed to house up to one particulate filter and five ion exchange filtersand five ion exchange filters
The screwed type design will minimize The screwed type design will minimize mechanical agitation during assembly and/or mechanical agitation during assembly and/or disassembly. disassembly.
Sample taken at high pressure to ensure Sample taken at high pressure to ensure corrosion products are not removed by the corrosion products are not removed by the pressure reducing valve pressure reducing valve
Pressure rating of 3000 psia (206 bar) and Pressure rating of 3000 psia (206 bar) and temperature of 149 F (65 C)temperature of 149 F (65 C)
SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection
ConclusionConclusion
Corrosion Products Samplers can be an Corrosion Products Samplers can be an invaluable resource to:invaluable resource to: Locate the sources of corrosion productsLocate the sources of corrosion products Determine the rate of corrosionDetermine the rate of corrosion Identify the type and cause of the corrosionIdentify the type and cause of the corrosion Track the path of corrosion productsTrack the path of corrosion products
ConclusionConclusion
Improve plant safety & equipment Improve plant safety & equipment reliabilityreliability
Increase plant efficiency and capacityIncrease plant efficiency and capacity Reduce frequency between routine Reduce frequency between routine
cleanings of plant heat exchanger cleanings of plant heat exchanger equipmentequipment
Reduce plant operating costs Reduce plant operating costs
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