Sample Conditioning System Design for Process Analysis

Importance
In order to obtain a reliable, representative and timely
process data, it is imperative to provide a continuous flow
of clean and dry sample. To many, this represents a
constant challenge, with sample conditioning units
frequently plug up with solids and others substances.
Increasing Maintenance cost - labour, and replacement parts-
and process and analytical downtime,
Criteria when Sampling
When designing a sample conditioning system, you must follow
these six criteria
1. Compatibility
a. ! compatible "ample will not harm the analyzers
and will produce a reliable analytical result
b. #auses for Incompatibility $oor design and
filtration, partial condensation, failure to
control temperature, pressure%high&, or flow,
inadequate materials against corrosion, heat,
pressure, etc
2. Timely
a. !lthough an analytical measurement is never
instantaneous %some time delay is inevitable&,
consider what an acceptable delay from real
process time is.
b. "ome delay are cause by Wrong port location,
volume, too long or stagnant line, high pressure,
low flow, dead legs, , slow analy'er, etc
c. (emember that the total time delay is the sum of
all the delays
3. Representative
a. ! sampling conditioning sample must provide sample
that is meaningful for its intended purpose.
(epresentative is not always accurate.
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b. $otential causes of lost representation are
#omposition change due to chemical reaction,
incomplete sapling at port, contamination by
adsorption or permeation, etc

4. Reliable
a. ! rule to remember, )eep it simple, *o I really
need it+
b. ,se parts that are easy to repair and maintained
c. -eep a regular maintenance schedule %filters,
valves, pumps, etc&
5. Cost!""ective
a. #onsider cost for maintenance, labour, operation,
spare parts, consumables, utilities and downtime
operation
#. Sa"e
a. !pply all safety procedures, when design a system
be careful not to expose the operator to ha'ardous
chemicals or radiation, or lethal voltage etc
b. Train the operator to handle the equipment.
$asic Sampling Con%itioning System
.. $ort %extraction point&
/. Tubing
0. $umps
1. 2ilters
3. 4eating components %4eating lines, heaters, insulation,
etc&
5. #ondensing components %cooler, moisture trap,
condenser, etc&
&rocess &ort 'ocation
When evaluating a sample port location, consider the
fallowing criteria
.. What is to be measured and why+ Is imperative to
understand the process %the closer the better&
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/. 6enerally, from the process viewpoint, ,pstream is
better %representative, timely&, but from the analy'er
viewpoint, *ownstream is better %#ooler, lower
pressure, easier to handle and cleaner& 7-ey word is
compromise.
0. 8rientation is also important9 place it in a way that
gravity will assist in removing solids or liquid drops.
1. -eep the no''le short as possible to minimi'e time
delay
3. -eep it simple and accessible for removal and
maintenance.

Sample Transport System
(emember these / basics rules
.. (ever sample or transport vapour streams at their dew
point
/. (ever sample or transport liquid streams at their
bubble point
0. )eep gases hot and liquids cold.
1. )now where the sample pressure drops.
&robes
! probe has three main purposes 6et the fastest
response, ta)e a selective sample, to ta)e a
representative sample. #onsider these criteria.
.. :ocation, ! rule of thumb is to have the tip of the
probe in the middle .;0 of the pipe diameter.
/. !void resonant vibration cause by the impact of
process flow. ! bro)en probe could damage a control
valve, pump, etc
0. In occasions a filter is fit in the probe<s tip, a
blowbac) system can be used to )eep the filter
unclogged.
*ain Concerns
.. #ondensation
/. Time delay
Types
3
.. single :ine "ystem
a. 6ood for short lines%=0> meters&
b. "traight line from sample port to analy'er,
sample is vented.
c. (emember that a gas compress under pressure, so
the volume flowing in the pressuri'ed line is
not the same as the flow rate measured by the
flow meters
/. 2ast :oop "ystem
a. Is used in applications where long lines need
high flow rates.
b. "ample is return to the process, not vented
&hase Separation
"pecific equipment is used, such as $article filters,
liquid separators, dryers for gas sample, degasser for
liquid samples.
&article Removal
.. "urface 2ilters
/. *epth 2ilters
0. fast loop filters
1. !xial flow filters
3. "wirl filter
5. cartridge filters
'i+,i% Removal
.. #ondensation caused for cooling the sample must be
removed before the sample reaches the analy'er.
a. 2or big volumes of liquid, use a )inetic
separator, using momentum and gravity to
separated condensation.
b. "ometimes a sample stream needs to remove
suspended liquid droplets, in this case used
a coalescer
c. Membrane filters, made from polymer that are
chemically inert and do not change the sample
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composition, it have micro pores that allow
gases ? vapour to pass, but act as a barrier
to liquids.
d. Membrane dryers, water vapour is removed by
transfer across the walls of a @AafionB
polymer tube. The dryer is built li)e a tube
in a shell exchanger and may contain many
tubes. *ry air or nitrogen purges the shell<s
walls removing the water. The water molecules
move to equali'e their partial pressure.
,sually the water is vented to atmosphere,
there is an issue with these membranes, the
sample gas must not be saturated, if water
gets into the tubes it renders ineffective.
&hase &reservation
!ll the sample states %6as, liquid, solid& are depending on
the surrounding pressure and temperatures
-as
Molecules are very far apart, therefore gases are
compressible
.apo,r
! vapour is a gas that is close to its dew point
temperature. Capours are therefore condensable.
'i+,i%
In these state, the molecules are quite close together
so liquids are not very compressible.
Soli%
"olids are incompressible and retain their shapes such
as crystals.
To avoid condensation used a heated filter, heated line and
maintain above dew point temperatures, even the analy'er
must be above dew point temperatures, remember that
insulation alone will not )eep a gas warm
Sample Switching *ani"ol%

When designing a switching manifold consider the following
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.. !ssume all valves will lea).
/. !void @dead legsB.
0. Maintain flow in supply lines.
1. ,se separate filter for each stream.
3. #ontrol flow;pressure of each stream.
5. ,se bypass for reducing lag.
D. :ocate gauge in bypass line.
E. :ocate lab. sample in fast loop.
F. ,se air operated ball valves, not solenoids.
.>. $rotect against vent pressure variations.
... Maintain adequate temperature.
./. Gnsure design meets safety codes.
.0. Minimi'e cost and complexity.
.1. Gnsure it is maintenance friendly.
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