Sentry Equipment Corp Sampling Solutions Specialty Heat Exchangers Gas and Liquid Sampling Applications.

Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers

Gas and Liquid Gas and Liquid Sampling Sampling

ApplicationsApplications


Applications ReviewApplications Review

• Refinery • Chemical• Wastewater• Mining Slurry• Pharmaceutical• Plastics• Milling and other


Refinery ApplicationsRefinery Applications


RefiningRefining

An oil refinery is an industrial process plant where crude oil is processed and refined into useful petroleum products.


Refinery ProcessRefinery Process


Common Process TermsCommon Process Terms

• LSRG = light straight run gasoline• LAGO = light atmospheric gas oil• HSRG = heavy straight run gasoline• CVGO = combined vacuum gas oil• LGO = light gas oil• CGO = combined gas oil• HGO = heavy gas oil• DHGO = Desulfurized or distilled heavy gas oil• KERO = kerosene• DLGO = Desulfurized or distilled light gas oil• CLAGO = combined light atmospheric gas oil• LAGO = light atmospheric gas oil


Refinery Process SimplifiedRefinery Process Simplified

•Separation•Conversion•Purification


CDU – Crude Distillation UnitCDU – Crude Distillation Unit

• CDU - an atmospheric pressure distillation tower. This unit accepts a variety of crude oils and distills them into the primary products including LPG, naphtha, kerosene, light gas oil and refined crude

• Heated crude condenses at various levels in the tower

• 250f• 150 psig


VDU – Vacuum Distillation UnitVDU – Vacuum Distillation Unit

• VDU or vacuum distillation unit is a vacuum distillation tower. This unit accepts “reduced” crude processed by the CDUs and distills them into the primary products including LPG, naphtha, kerosene, light gas oil and refined crude

• 700 F typical• 100 psig


VBC – Visbreaking UnitVBC – Visbreaking Unit

• VBC or Visbreaker is a thermal cracking unit. This unit accepts vacuum tower “resid” or the very viscous vacuum tower bottoms and uses high heat (800 F) to crack the hydrocarbons into fuel oil, naphtha and light gas oil

• 800 F typical• 100 psig• Typically a patented

process (UOP, shell)


HTU – Hydrotreater UnitHTU – Hydrotreater Unit

• HTU or Hydrotreater uses a recycled hydrogen stream and catalyst to convert sulfur compounds to hydrogen sulfide, nitrogen to ammonia and aromatic hydrocarbons to stronger hydrocarbons. This unit accepts vacuum tower light and heavy gas oil and converts them to gasoline, kerosene and naphtha

• 200 F typical• 200 PSIG liquids• 1300 PSIG gases


CRU – Catalytic UnitCRU – Catalytic Unit

• CRU or catalytic reforming unit removes oxygen, nitrogen and sulfur from naphtha that contaminates the unit’s catalyst and then converts it to gasoline

• Up to 500 F typical• 200 PSIG liquids• Typically a

patented process (“Unifiner”, etc.)


SRU – Sulfur Recovery UnitSRU – Sulfur Recovery Unit

• SRU or sulfur recovery unit converts hydrogen sulfide into elemental sulfur

• Up to 200 F typical• 100 PSIG liquids


FCCU – Fluid Catalytic Cracking FCCU – Fluid Catalytic Cracking UnitUnit

• Fluid catalytic cracker (FCC) uses high temperature and catalyst to crack heavy gas oil mostly into gasoline. Hydrocracking uses catalysts to react gas oil and hydrogen under high pressure and high temperature to make both jet fuel and gasoline

• Up to 200 F typical• 100 PSIG liquids


Polymerization UnitPolymerization Unit

• Polymerization in the petroleum industry is the process of converting light olefin gases including ethylene, propylene, and butylene into hydrocarbons of higher molecular weight and higher octane number that can be used as gasoline blending stocks.

• Polymerization combines two or more identical olefin molecules to form a single molecule with the same elements in the same proportions as the original molecules. Polymerization may be accomplished thermally or in the presence of a catalyst at lower temperatures.


Alkylation UnitAlkylation Unit• Alkylation combines

low-molecular-weight olefins (primarily a mixture of propylene and butylene) with isobutene in the presence of a catalyst, either sulfuric acid or hydrofluoric acid

• For fuels blending• Various process

methods


Other Processing UnitsOther Processing Units

• Amine plant Amine removes sulfur and other impurities

• Hydrogen plant Recovers hydrogen from the processes and

stores it along with additional H2 for hydrotreating

• LPG - liquid petroleum gas plant Recovers petroleum gas products, refines them

and blends them for distribution as a liquid• MTBE – methyl – tertiary- butyl- ether plant

Generates MTBE from methanol and process gasses

Used as a fuel additive


Typical Sampling Points and Typical Sampling Points and SamplesSamples



Sample Name

Sample Constituents

Phase Temp (F)

Pres.psig

Recommend Sampler Problems/Concerns

Observed Samples

Desalter In Crude Oil Liquid 90 70 MVD Liquid Sampler Product waste, environmental, messy

Desalter Out Desalted Crude Oil

Liquid 200 to 250

70 MVD Liquid Sampler Fumes from chemicals added to break the oil water emulsion (Betz W906), The Betz product requires PPE including respirator if the chemical is about 220 F. Cooler is inefficient and suffers from corrosion. Samples are sometimes hot.

Desalter water

Water, steam, oil

Liquid/Vapor

200 130 MVD Liquid Sampler Sample is too hot when a proper flow rate is attained; long sample line runs in 1” O.D. pipe

LSRG Gasoline Liquid 100-200

150 MVD Liquid Sampler Temperature, “representativeness” of sample, fumes

HSRG Gasoline Liquid 100-200




LGO Oil Liquid 100-200


HGO Oil Liquid 100-200


KERO Kerosene Liquid 100-200


Resid Out Bottoms Viscous Liquid

90 40-60

MVD Liquid Sampler Fumes, mess

Caustic Soda Caustic Soda in water

Liquid 100 100 MVD Liquid Sampler Hazardous, “representativeness” of sample


VDU – Vacuum Distillation UnitVDU – Vacuum Distillation UnitSample Name Sample

ConstituentsPhase Temp

(F)Press. (psig)

Recommended Sampler Problems/Concerns

Observed Samples

Gas Oil Oil Liquid 100-200

150 MVD Sampler Product waste, environmental, messy


150 MVD Sampler Temperature, “representativeness” of sample, fumes

Blended Resid Oil, Vacuum tower bottoms

Liquid 200 100 Heavy liquids sampler Sample is too hot when a proper flow rate is attained; long sample line runs in 1” O.D. pipe

Vacuum tower bottoms

Oil, tar Liquid 540 100 Heavy liquids sampler Sample is too hot when a proper flow rate is attained; long sample line runs in 1” O.D. pipe, location of sample point traps operator, splashes, drain plugging

Sour Gas Oil Oil with H2S Liquid 708 46 MVD Sampler Temperature, “representativeness” of sample


VDU – Vacuum Distillation UnitVDU – Vacuum Distillation UnitBoiler Blowdown

Water Liquid 300 150 SL Panel Temperature, “representativeness” of sample, fumes

HVGO Oil Liquid 100-200


Naphtha Naphtha Liquid 100-200


CLAGO Light Gas Oil Liquid 100-200


CVGO Heavy Gas Oil Liquid 100-200


LAGO Light Gas Oil Liquid 100-200


Sour Water Water + H2S Liquid 125 60 MVD Sampler Temperature, “representativeness” of sample, H2S fumes

Resid Out Bottoms Viscous Liquid

90 40-60

Heavy liquid sampler Fumes, mess


VDU- VisbreakerVDU- Visbreaker

Sample Name Sample Constituents

Phase Temp (F)

Press. (psig)

Recommend Sampler Problems/Concerns

Observed Samples

Visbreaker bottoms

Oil, tar Liquid 460 100 Heavy liquid sampler Sample is too hot when a proper flow rate is attained; long sample line runs in 1” O.D. pipe, location of sample point traps operator, splashes, drain plugging

Visbreaker off gas

Hydrocarbon gas + H2S

Gas 100 40 MCL/MCG sampler “representativeness” of sample, fumes, difficult sample to obtain

LVGO Light Gas Oil Liquid 100-200

100 MVD Liquids sampler Temperature, “representativeness” of sample, fumes

CVGO Heavy Gas Oil Liquid 250 100 MVD Liquids sampler Temperature, “representativeness” of sample, fumes


HTU- HydrotreaterHTU- HydrotreaterSample Name Sample


(F)Press. (psig)


Observed Samples


80

MVD Liquid Sampler Temperature,

“representativeness” of sample, fumes

Naphtha Naphtha Liquid 100-200


DCGO Gas Oil Liquid 100-200


DHGO Heavy Gas Oil Liquid 200 180 MVD Liquid Sampler Temperature, “representativeness” of sample, fumes

DLGO Light Gas Oil Liquid 200 180 MVD Liquid Sampler Temperature, “representativeness” of sample,

Hydrogen H2 Gas Ambient

1300 MCL/MCG sampler Pressure, “representativeness” of sample, explosive

Recycled Process Gas

H2 + H2S Gas 100-200

1200 MCL/MCG sampler Pressure, “representativeness” of sample, explosive

RX Effluent Oil + Gas + H2S Multi-phase

100-200

100 MCL/MCG sampler Pressure, “representativeness” of sample, fumes

Refractionater Off Gas

CH4 Gas 100 6 MCL/MCG sampler Pressure, “representativeness” of sample, flammable

Charge LVGO + HVGO Liquid 100-200

80

MVD Liquid Sampler Temperature,

“representativeness” of sample, fumes

Condensate Water Liquid 100-200

100 MVD Liquid Sampler Temperature, “representativeness” of sample


SRU – Sulfur Recovery UnitSRU – Sulfur Recovery Unit

Sample Name

Sample Constituents

Phase Temp (F)

Press. (psig)


Observed Samples

Sour Gas H2S Gas 100-200

15 MCL/MCG Sampler Temperature, “representativeness” of sample, fumes, ammonia salts

Amine Acid Gas

Amine Gas Gas 200 15 MCL/MCG Sampler Temperature, “representativeness” of sample, fumes, ammonia salts

Hydrogen Sulfide

H2S Gas 100-200

150 MCL/MCG Sampler/Drager tube sampler

“Representativeness” of sample, fumes

Condensate Water Liquid 100-200

100 MVD Liquid Sampler Temperature, “representativeness” of sample


CRU – Catalytic Reformer UnitCRU – Catalytic Reformer UnitSample Name Sample


(F)Press. (psig)


Observed Samples

*Unifiner Bottoms

Aromatics, Paraffins, Naphins, Olefins

Liquid 210 140 Heavy liquid sampler, ISOLOK®

Temperature, “representativeness” of sample, fumes, waste (6-8 liters per sample)

Unifiner Charge Kero or Oil Gas

Liquid 100 500 MVD liquid sampler High pressure, poor location

Unifiner charge Naphtha Liquid 210 140 MVD liquid sampler Temperature, “representativeness” of sample, fumes, waste (6-8 liters per sample)

Unifiner stripper bottoms

Aromatics, Paraffins, Naphins, Olefins

Liquid 210 140 MVD liquid sampler Temperature, “representativeness” of sample, fumes, waste (6-8 liters per sample)

Unifiner stripper off gas

Hydrocarbon gas + H2

Gas 100 380 MCL/MCG Sampler Representativeness” of sample, explosive, waste

Platformer Recycle Gas

70% H2 Gas 100 380 MCL/MCG Sampler Representativeness” of sample, explosive, waste


LPG – Liquid Petroleum Gas UnitLPG – Liquid Petroleum Gas UnitSample Name Sample


(F)Press. (psig)


Observed Samples

Depropanizer Tops


Gas Unk Unk MCL/MCG Sampler Hazardous, representative

Depropanizer Bottoms



Caustic Soda Sodium Hydroxide

Liquid Unk Unk MVD Liquid sampler Hazardous, representative

Depropanizer Off gas



Deethanizer off gas



Condensate Water Liquid Unk Unk SL Panel


Amine UnitsAmine Units

Sample Name Sample Constituents

Phase Temp (F)

Press. (psig)


Observed Samples

Lean Amine DEA, H2S Liquid Unk Unk MVD Liquid Sampler Representativeness” of sample, health risk

Rich Amine DEA, H2S Liquid Unk Unk MVD Liquid Sampler Representativeness” of sample, health risk

Regen Reflux DEA, H2S Liquid Unk Unk MVD Liquid Sampler Representativeness” of sample, health risk


Simplified Refinery ProcessSimplified Refinery Process


Other Processing UnitsOther Processing Units

• Hydrogen plant

MCL/MCG sampler• LPG - liquid petroleum gas plant

MCL/MCG sampler with outage volume• MTBE – methyl – tertiary- butyl- ether plant

MVD sampler• Marine terminals

ISOLOK®• Tank farms

ISOLOK® Back purge tank sampler


Reasons Refineries SampleReasons Refineries Sample

• Confirm unit operation

Quality control and custody transfer between units and customers

• Environmental control and compliance• Process control (catalyst, heat exchanger, unit

performance) “did I remove enough sulfur?” “Did I get enough C & H out?”

• Waste water treatment loading


Keys to Refinery SamplingKeys to Refinery Sampling

• Speed loop• Open • Cooling (60 C - 149 C)• Pressure reduction


Typical Materials SampledTypical Materials Sampled

Refinery Petrochemical/Chemical Cracked Gases Aromatics Liquids Products Organics Plastics Inorganics Fuels

Acetylene Benzene Paraffins Gasoline Acids Monomers Nitric Acid Gasoline

Propylene Toluene Naphthalene Kerosene Alcohols Solvents BTX

Butane Xylenes Gas-Oils Oils Aldehydes

Naphthalene Bottoms Amines

Aromatics

Glycols

Ketones

Phenols


Keys to Refinery SamplesKeys to Refinery Samples

• Speed loop• Open• Cooling (60 °C – 149 °C)• Pressure reduction


Chemicals/PetrochemicalsChemicals/Petrochemicals

• Acetic Anhydride– Methanol feedstock– Used to make cellulose acetate and

plastics– Aspirin & pharmaceuticals

• Hazardous to breathe and skin contact• Corrosive• MVD, MFV, MIL



• Methanol– Feedstock is coal and natural gas– Used to make acrylic polymers and

solvents• MVD, MCG



• Acetic acid– Base for aldehydes– Primary production in Asia is for use

in composite wood adhesives and other adhesives

• MVD, MIL, MFV



• Monostyrene– Plastics

• MFV, MVD



• PX (Paraxylene)– Feedstock is refinery reformate

gases– Benzene– Primary use: Polyester

• MFV, MVD, MCG


Why Use Sentry Samplers?Why Use Sentry Samplers?

• Operator safety• Environmental safety• Sample is representative of the process• Easy operation• Low maintenance• Eliminates spills


Industry TrendsIndustry Trends

• North America– Government low sulfur fuels rules – now and on-going– Local environmental and emission requirements –

California (bay area air quality management district)• International

– Want to meet north America’s rules to sell to market• All

– Crude is increasingly sour (high in sulfur)– Crude is increasingly harder and more expensive to

get– See above

• New processes are being developed to meet the new low sulfur requirements and to make sulfur removal more efficient

• Fuel blending


MVD Sampler With Box and MVD Sampler With Box and HeaterHeater


MVD Sampler With Sample MVD Sampler With Sample CoolerCooler


MFV SamplerMFV Sampler


MCL SamplerMCL Sampler


MCG Sampler for GasesMCG Sampler for Gases


Wastewater ApplicationsWastewater Applications


Wastewater – Process flow


Typical Sampling Points Typical Sampling Points

• Outlet of settling tank

• Solids outlet of clarifier

• Outlet of digester


Why Sample in a Wastewater Why Sample in a Wastewater Plant? Plant?

• Control solids ratios at the digesters – 70% of plant costs deal with the

removal of solids– Digesting sludge reduces solids volumes

thus, less to incinerate• Improve overall plant efficiency• Cost control• Truck load out verification

– Hauling costs are based on lbs of liquid– Control the concentration of solids


Challenges With Sampling in a Challenges With Sampling in a

Wastewater PlantWastewater Plant

• Stinky and sloppy job– Spigot under pressure = VERY MESSY!

• Manual samples are not representative due to human variances and operators attempt to reduce messes

• Dozens of sampling points result in high labor costs and inaccuracies (due to inconsistent composite samples)

• Ergonomics (the ideal sample point is not always located in an easily reachable location)


• ISOLOK® is the only sampler that can effectively sample sludge from a pressurized line

• Automatically captures fixed sample volume at fixed time intervals providing uniformity and consistency of sample for process control (elimination of human error)

• Unit is simple, safe, and reliable• Clean (eliminates material spillage)• VERY low labor costs

– Each MANUAL grab sample typically takes 10 minutes (including clean up) every couple of hours

– Sampling with the ISOLOK® typically only requires operators to collect the containers ONCE per day!

Why the Why the ISOLOK®ISOLOK®? ?


Mining SlurryMining Slurry

• Abrasive• Corrosive due to acids, bases used to

extract minerals• Particle size


ISOLOK®ISOLOK® in Shell Oil Sands in Shell Oil Sands


Pharmaceutical ApplicationsPharmaceutical Applications


Typical Pharmaceutical Process FlowTypical Pharmaceutical Process Flow






Typical Sampling Points in a Typical Sampling Points in a Pharmaceutical PlantPharmaceutical Plant

• Reactor vessels – Top Reactor Sampler

• Pipes/tanks – MBP–Tank farms–Process piping

• Solvent recovery - MVD


Reactor Vessel Sampling Reactor Vessel Sampling

• ISOLOK®• Top reactor

sampler• Back purge tank

sampler• HPI sampler

















Pipe / Tank SamplingPipe / Tank Sampling

• Incoming raw material at truck unloading station – Generally sample for custody transfer reasons

• Tank farm– Sampling of individual ingredients prior to

transfer to the make tank

• Process piping – Quality control checkpoints along the process






Solvent RecoverySolvent Recovery


Why Sample in a Why Sample in a Pharmaceutical Plant?Pharmaceutical Plant?

•Custody transfer •Process control•Chemical analysis


Challenges With Sampling in a Challenges With Sampling in a Pharmaceutical PlantPharmaceutical Plant

• Obtaining a representative sample from a lined reactor with high process temperature and pressure / vacuum

• Extracting sample from a device with a moving agitator

• Often requires special materials of construction– Hastelloy, titanium, AL6XN, etc

• Many sample points require “closed” sampling to eliminate operator exposure to hazardous conditions


• Wide variety of materials of construction available to satisfy process conditions – Special alloys– Seal materials

• Ability to offer closed sampling solutions when required – Needle/septum samplers– ISOLOK®® - exchanged air is returned to

process through sample annulus

Why Sentry Samplers? Why Sentry Samplers?


Plastics ApplicationsPlastics Applications Liquid Resin


Liquid ResinLiquid Resin

High performance liquid resin is used in such things as bowling balls, boat hulls, etc.


Challenges With Sampling in a Challenges With Sampling in a

Plastics Plant?Plastics Plant?

• Pressure or vacuum isolation• Viscosity• Carry over• Sample port/valve plugging• Temperature

– During and after sample


Typical Sample PointTypical Sample Point

• Sample from a jacketed reactor

• Sample point is located in a recirculation/speed loop

• Sample must remain hot to avoid setting


Liquid ResinLiquid Resin• Sampler is located in an

enclosure and is heat jacketed

• Sample drops into a container and is allowed to cool and set

• Customer takes the sample back to lab and re-melts for analysis


• Ability to handle high viscosity fluids• Easily heat jacketed• Can withstand high pressures and

temperatures while isolating the process and environment from each other

• Automatically takes fixed volume of material at fixed time intervals

• Simple, safe, and reliable• Clean (eliminates material spillage)• VERY low labor costs• Provides accurate verification for plant

control



Milling and other ApplicationsMilling and other Applications

• High fructose syrups (corn, beet)• Soy oil refining process• Byproduct streams• Process waste streams


Why Sample in Milling Why Sample in Milling Processes? Processes?

• Quality Assurance• Custody transfer• Process control• Effluent discharge regulations


Why Sample in Milling Why Sample in Milling Processes? Processes?

• 3-A Designated Samplers– M4KSA– MSA– MSD– MSC– MSE

• FDA Components; Seals and materials


Challenges With Sampling - Challenges With Sampling - Milling ProcessesMilling Processes

• Process flow volume can vary so sampling frequency must vary accordingly

• Process chemicals require exotic materials for wetted components

• Manual samples are not representative due to human variances and operators attempt to reduce messes

• Dozens of sampling points result in high labor costs and inaccuracies (due to inconsistent composite samples)

• Ergonomics (not always feasible to sample proportionally with the operation of other process equipment)


• Simple, safe, and reliable• Uniformity and consistency of sample• Elimination of human error• Clean (eliminates material spillage)• Can be controlled to proportionally

operate with other process equipment • Provides accurate verification for plant

and governmental control



Dairy ApplicationsDairy Applications


Typical Sampling Points in Typical Sampling Points in Dairy Application Dairy Application

•Raw milk receiving at truck unloading dock –Close to milk pump discharge


Why Sample in Dairy Applications?Why Sample in Dairy Applications?

• Payment calculation for farmer– Butter fat content– Protein– Other solids

• Bacteria level• Hormone levels (BGH)• Antibiotics


Challenges With Sampling in Dairy Challenges With Sampling in Dairy ApplicationsApplications

• Equipment must be 3-A compliant – (Section 59-00 of 3-A code)

• Must be easily removed and cleaned without the use of tools

• Sample should be taken proportional to flow rate to ensure sample is representative of the entire truckload

• May require sampler to turn on/off with milk pump


• Sentry is the only U.S. Based manufacturer with section 59-00 3-A approval – (Model M4-KSA and MSA samplers)

• Unit can be easily removed and cleaned without the use of tools

• Sampler automatically takes small fixed volume per stroke (typically 3cc) frequently throughout the entire truck unload process to ensure sample composite is representative of the entire truckload



Dairy ApplicationsDairy Applications


Questions?Questions?

Sentry Equipment Corp Sampling Solutions Specialty Heat Exchangers Gas and Liquid Sampling Applications.

Documents

psig slide

light gas oil cgo

oil refinery

high heat

heavy gas oil dhgo

heavy gas oil kero

light atmospheric gas

combined gas oil hgo