4 Sampling of Steam and Water For Chemical Monitoring and Analysis

LMI/NPGC/CHEM/OGN/OPS/011
LOCAL MANAGEMENT INSTRUCTIONS
Sampling of Steam and Water for

Chemical Monitoring and Analysis
NPGC-Nabinagar
TECHNICAL COMPLIANCE SYSTEM

LOCATION MANAGEMENT INSTRUCTIONS
LMI/NPGC/CHEM/OGN/OPS/011
TITLE OF LMI Sampling of Steam and Water for Chemical Monitoring and Analysis
Revision No.: 0
September 2018
Sampling of Steam and Water for

Chemical Monitoring and Analysis
Approved for Implementation by CEO (NPGC)

LMI NO. LMI/NPGC/CHEM/OGN/OPS/011
PREPARED BY SIGNATURE: ………………………………….
CHECKED BY SIGNATURE: ……………………………………
HOD (CHEM)
REVIEWED BY SIGNATURE: ……………………………………
GENERAL MANAGER (O&M)
APPROVED BY SIGNATURE……………………………………..
CEO
NPGC - NABINAGAR ,
AURANGABAD (BIHAR)
Sampling of Steam and Water for Chemical
Monitoring and Analysis
CONTENTS
Page Nos.
1.0 Introduction 1
2.0 Superseded Documents 1
3.0 Scope 1
4.0 Reference Document 1
5.0 Instructions 1
6.0 Review 10
7.0 Revision Index 10
8.0 Distribution List 10

Page 1
LMI/NPGC/CHEM/OGN/OPS/011 Revision No.: 0

Sampling of Steam and Water for Chemical Monitoring and Analysis
SAMPLING OF STEAM AND WATER FOR CHEMICAL

MONITORING AND ANALYSIS
1.0 INTRODUCTION :
Water conditioning (Quality of Steam & Water) in the Thermal Power Units is of
utmost important and essential for the healthy running of Power Station. It ensures
the longer and trouble free life of the equipments and system. In order to have a
check on quality of steam and water in the system, it is significant to standardize the
sampling points, frequency of sampling and procedure of sampling and testing.
2.0 SUPERSEDED DOCUMENTS :
Nil
3.0 SCOPE :
The document provides guidance on various aspects relating to the conditioning of

samples of steam and water at NPGC Stage I (3x 660 MW).
4.0 REFERENCE DOCUMENT :
OPERATION GUIDANCE NOTE : COS-ISO-00-OGN/OPS/CHEM/011

Page 2

Issue No. 1 Dated August’1999.
5.0 INSTRUCTIONS:
5.1 DEFINITIONS :
For the purposes of this LMI, the following definitions will apply :
a) ISO Kinetic Sampling
A technique in which the sample from a fluid stream passes into the orifice of a
sampling probe with a velocity equal to that of the stream in the immediate vicinity
of the probe (Isokinetic Sampling)
b) Sampler
A device used to obtain a sample of water or steam, either discretely or

continuously, for the purpose of examination of various defined characteristics.
c) Sampling Point
The precise position within a system from which a sample is taken.

Page 3

d) Sampling Probe
That part of sample equipment, which is inserted into a body of steam or water and
into which the sample initially passes.
e) Sampling Line
The conduit which leads from the sampling probe to the sample delivery point or the
analyzing equipment.
f) Sampling Delivery Point
The end of a sampling line often remote from the sampling probe, from which a
sample is removed, either discretely or continuously, for examination.
5.2 SAMPLING EQUIPMENT – TERMINOLOGY
Historically, sampling equipment has fallen into two categories :
i) So-called fast sampling equipment in which the flow rate is controlled by the use
of one or more pressure regulating valves.
ii) Capillary sampling equipment in which the pressure and volume flow rates are
controlled solely by the length and bore of capillary tube which forms an integral
part of the sampler.
While “fast” sampling equipment is recognized as appropriate for the sampling of

water for soluble components, capillary sampler were originally developed for the
Page 4

sampling of particulates, taking into account the desirability, firstly to simple

isokinetically and secondly, to minimize subsequent deposition of the particulates in
the sample line. As a consequence, the terms, ‘isokinetic’ and ‘capillary’ have
become almost synonymous when used in this context and the tendency has arisen
to associate only this type of sampler with the sampling of particualtes – whether in
water or steam. However, in some power stations, ‘fast’ samplers have been used
successfully to abstract two-phase samples under essentially isokitietic conditions
and conversely, capillary systems have also been used for sampling water for
soluble components. These designs allow for the sampling of both soluble and
particulate matter in water at pressure upto 300 bar and in steam at a maximum
pressure of 200 bar. Here, samplers are referred to as Types W1-W4 (for water) and
S1-S2 (for steam). Guidance on this use and application is provided by this LMI.
5.3 WATER SAMPLING
A) General
A pre-requisite of any sampling system is that it should extract a sample

representative of the fluid in the system for subsequent analysis. Problems are most
likely to arise when more than one phase is present.
a) Samples at different stages of steam water cycle of Unit I to III shall be collected
from the existing sampling points. Samples of feed water, Boiler water, Stage-I,
SS,SHS of Unit-I, II & III are collected from boiler side at 8 meter level of
respective unit. Condenser samples of these units are collected at the discharge of
condensate P/P sampling points provided at zero meter in the turbine side.
Samples of feed water, boiler water, SS, SHS shall be collected at 18 meter
(boiler side) for Unit- I, II & III . Condensate samples of Unit- I, II & III shall be
collected at zero meter.The samples of stator water of Unit-I, Unit-II & Unit-III
shall be collected from their respective sampling points provided at zero meter.
The samples of UDT of all the units shall be collected from the respective
sampling points provided at zero meter near the unit drain tanks. While collected
Page 5

the various samples if it is observed that steam is also coming along with a
particular water sample, the sample shall not be collected and the matter shall be
informed to shift In-charge and BMD for the purpose of attending to the problem
and its rectification. However, the same sample shall be collected from the on line
analyser point if provided in the turbine side at zero meter.
b) In case new sampling points are to be provided or the existing sampling points
are to be modified the following shall be complied.
Page 6

A) Sampling soluble species
In instances where the subsequent analysis is for soluble species, a sampler of type
W1, W2 or ?W4 should be chosen, depending upon the pressure of the system. With
samplers W1 and W2 installed as recommended, i.e. with the inlet slot facing away
from the direction of flow, ingress of particulates is minimized and thus deposition
and the risk of blockage within the sample line reduced. The need for this applies
especially where long sample lines are used to route samples to the on-line
instrumentation.
B) Sampling Particulate Species.
Representative sampling of particulates in water is important when analysing for

corrosion products of, for example, copper, iron or nickel. Such analysis may be
required, for example, to assess the extent of erosion or corrosion in the system, or
the efficiency of chemical conditioning. Ideally, sample abstraction should be at, or
near, isokinetic flow rates. Also, although Sampling systems with control valves are
widely used, it is essential to avoid the problem of deposition of the particulate
material in valves or stagnant regions of the sampler itself. For this reason, samplers
have been developed which use the fractional drag of the internal surfaces of a
Stainless Steel capillary valve. Capillary samplers, however, require a high level of
attention, with respect to both their installation and maintenance. They are,
therefore, best regarded as scientific instruments rather than station hardware and
should be treated accordingly.
In some instances, a practical alternative to using capillary samplers is to use

samplers as appropriate to the pressure) but with the inlet slot directed to face into
the flow. If this approach is adopted, it should be recognized that experimental
evidence suggests that the results from samples obtained in this mariner may be
biased low compared with those obtained from capillary samplers. This is probably
due to a combination of factors, such as a departure from isokinetic conditions and
possible increased deposition in the sample lines.
Page 7

For pressure upto 40 bar, a combined wide bore and capillary sampler is available.
By requiring only one entry point into the feed-line installation is easier and there is
minimum interference with the mechanical integrity of the feed pipe walls.
However, samplers are fined with two identical capillaries, so that should one
become irreversibly blocked, the other may be used until such time as the unit
comes off load and a replacement can be fitted.
C) Positioning and Installation of Samplers
There are numerous locations ‘in power station where steam and water sampling is
required. Care should be taken in choosing the right type of sampler and
determining its proper positioning to suit the particular application. Generally,
sampling points should be chosen so as to avoid dead spaces and sections of the
plant, which are likely to be bypassed.
a) Type W1 and W2
There is no evidence that the siting of Types W1 and W2 for sampling of soluble
components is critical, other than to ensure that they are sufficiently downstream of
an injection point of, a chemical or water stream for complete mixing to have
occurred. However, when Type W2 is used in conjunction with a Type W3 sampler
(e.g. for assessing the overall efficiency of feed-water treatment), it should be sited
adjacent to, but downstream of this sampler.
b) Type W3 and W4
Page 8

The principal use of samplers with capillary tubing is for the representative
sampling of suspended solids in water. When used for this purpose, it is important
that these samplers should be unaffected by disturbances in the main flow. Ideally,
Types W3 and W4 samplers should be located in vertical sections of system pipe
work with an ascending flow and at least five diameters before and ten diameters
after bends, valves and ventures, etc. However, in a modern power station plant, it
may be difficult to satisfy this condition. Consequently, where the ideal point cannot
be found, the samplers should be sited two-thirds of the way along the longest
straight pipe in the relevant section of the system pipe work.
c) Boiler Water Sampling
Boiler water sampling on some stations is achieved using a multi-tube sampling

arrangement mounted so as to obtain a representative sample along the length of the
drum. Whilst this may be adequate, an arrangement by which samples are taken
using the Type W2 sampler from a number of down corners and subsequently
combined by means of a manifold system, is much preferred. This ensures that the
sample taken for analysis is more representative of the water reaching the
evaporative surfaces of the boiler.
The W2 sampler should be positioned such that its inlet is away from the direction
of flow.
5.4 STEAM SAMPLING
A) General
One of the principal problems with steam sampling, particularly saturated steam, is
that there are large density differences between the phases. There may also be
problems of solids deposition at the initial stages of steam condensation.
Page 9

B) Sampling Saturated Steam
With the sampling of saturated steam, the additional problems of coalescence and
condensation militate against representative sampling. Nevertheless, there are
measures which can be taken to reduce errors. Firstly, it is best to sample from a
number of steam risers from the drum, combining the samples into one by means of
a manifold, before passing the combined sample to a cooler for condensation and
subsequent transport and/or collection. Secondly, it is recommended that the Type
S1 steam sampler be used for this purpose with sample flows adjusted to give
isokinetic sampling conditions at the sample inlet. In this case, the sampler orifice
should face the direction of flow.
The preference is for any valves to be mounted on the samplers but if the sampler is
mounted at a location which is not accessible in normal operation, then the valves
should be mounted along the sample line at the first accessible point.
C) Sampling Superheated Steam
There are two types of superheated steam samplers. Type S1 is more suitable for
insertion in small diameter pipes as part of multipoint sampling system, in which
flows are combined to provide adequate samples for analysis and Type S2 is more
appropriate where it is required to obtain a good, average sample from a single
penetration into one large bore pipe. In both instances, a cooler should be installed
immediately after the isolating valve. Sample flow rates should be adjusted to give
“isokinetic” sampling conditions or, alternatively, by a length of capillary installed
at the cooler outlet. In the latter instance, the length of capillary required can be
estimated, using the procedure given in Annexure. The use of a capillary device is
more suitable for local manual sampling.
It should be remembered that the cooling water requirement for condensing and
cooling superheated steam samples are considerable and consequently, every effort
Page 10

should be made to keep the sample volume flow rate to the minimum necessary for
analytical demands. As a guide for 1 kg/min of sample, 57 KW of heat need to be
dissipated. With superheated steam at 160 bar and assuming a cooling water Inlet
temperature of 20 deg C, a cooling water rise of 15 deg. C and counter current

cooling, this corresponds to a cooling water, flow rate of 54 kg/min.
5.5 USE OF CAPILLARIES FOR SAMPLING
A) General
Capillaries are a feature of water samplers and, are used as a means of reducing the
sample pressure and controlling flow rate without the need for valves, which helps
avoid the problem of deposition. They require special and careful treatment,
however, in respect of both installation and use.
B) Method of Preventing Blockage
Total blockage can best be prevented by ensuring that :
i) The sampling system is correctly installed with the

minimum of horizontal runs.
ii) Cooling water supplies are adequate and reliable.
iii) Regular flow rate checks are made to identify partial blockages.
Unless samples for the analysis of particulate matter are required during period of
heavy debris levels, i.e. start-up or commissioning, the capillary should be blanked
off using a suitable nipple and compression fitting.
Page 11

5.6 SAMPLE ABSTRACTION FOR MANUAL ANALYSIS
A) General
The individual methods also describe suitable methods for cleaning sampling
vessels. Once cleaned, precautions should be taken to ensure that they remain clean.
In many cases, this can be done by enclosing the vessels in polyethylene bags.
B) Sample containers and storage
The determination of trace impurities in high purity water imposes stringent

requirement on all aspects of the analytical process. Contamination can occur, for
example, from the atmosphere, from handling and by leaching from poorly Cleaned
containers. On the other hand trace constituents can be lost during storage by
volatilization, precipitation or absorption on to the container walls. The latter
phenomenon can occur, particularly with those species such as transition metal ions,
which will hydrolyse if the sample is not sufficiently acidic.
Commercially available plastic container have been found adequate for storage of
high purity water for periods of upto 8 days although contact time with any
container material should be kept to a minimum. Plastic containers are necessary for
the determination of ionic species such as sodium and potassium in stored grab
samples, but unsuitable for dissolved gas and total organic carbon analysis.
Suggested plastic container materials include polystyrene, polypropylene and
polyethylene.
Boro silicate glass containers are recommended for storage of water samples for
total organic carbon (TOC) determinations. They may be cleaned and sterilized in
accordance with ASTM D-3694.
Page 12

Sample bottle cleaning is essential to achieve reliable grab sample analysis. A

suitable procedure is as follows :
Flush the container with demineralised water at least three times, then fill
completely, cap and allow to soak for at least 1 day, but not more than 5 days. If 5
days storage is exceeded before use, the container should be refitted with fresh, high
purity water. The high purity water is left in the container until sampling. It is
advisable that plastic gloves be worn throughout the cleaning, sampling and transfer
of the sample to the analytical instrumentation to avoid contamination from the
hands. This is particularly the case for sodium and chloride analysis.
C) Sampling Line Purging before Sample Abstraction
Although samples with capillary sampling lines are continuously running, this may
not be the case with other types of sampler. Therefore, if the sample line is closed
off by a stop valve, the line must be purged for sufficient time before a sample is
collected. This is to ensure that a representative sample is obtained. A sample flow
rate of about 500 ml/min, cooled to less than 40 deg C, should be maintained.
Whenever samples are being collected, it is essential, especially for particulates that
there are no mechanical or pressure shocks to the system which could cause
excessive amounts of solid Material to be transferred to the sample container.
D) Liquid Samples (Other than those taken from capillary lines)
The sampling procedure for liquid samples should be as follows:
Empty the soak water from the sample container and rinse at least three times by
filling it to about ore-quarter capacity with sample water, shake, then empty the
container. When sampling for dissolved solids, the sample should be collected with
Page 13

the end of the sample tubing at the mouth of, but not touching the sample bottle. The
sample should not come in contact with the outside of the sample tube. When
sampling for organics or for atmlospheric constituents, the grab sample should be
collected by an upward displacement through a tube extending to the bottom of the
container. Allow the container to overflow at least five volumes, then close the
container with a cap which has been rinsed with the sample water.
E) Sampling Liquids for Particulates, using samplers with capillary lines.
The sampling vessel should consist of a polyethylene bottle with polyethylene cap
previously cleaned as described in the method (e.g. for nickel, iron or copper). A
hole should be drilled in the polyethylene cap and a length of PVC tubing shall be
tightly fitted through the cap with 25mm of tubing projecting into the bottle. The
I.D. and O.D. of the PVC tubing should be such that it will fit snugly over the end of
the capillary sampling line. The most suitable length of this sampling tube will vary
depending on local conditions at the sample delivery point, but about 13mm
projecting out of the cap should be adequate. If necessary, this length can be
increased to about 100 mm. One 6 mm length of PVC tubing of I.D. approximately
that of the above PVC tubing is pushed over the PVC sampling tube until it is flush
with the external surface of the cap and another 6 mm length pushed against the
internal surface of the cap. These two 6 mm sleeves are cemented to the inner
sampling tube with PVC cement or cyclohexanone, thus ensuring that it is held
tightly in position. The bottle is calibrated for the desired volume of sample and
then the bottle and cap are cleaned according to the instructions given with each
method. After cleaning the bottle is covered with a polythene bag held in place by a
rubber band.
To collect a sample the correct amount of acid, as indicated in the method, is added
to the bottle and the polythene cap and the bag is replaced. A hole is punchured in
the bag by means of the capillary tip, previously washed with distilled water and the
capillary tip securely connected to the PVC tubing. It is essential that the tip of the
capillary be as smooth as possible to avoid cutting the plastic tubing and thereby,
possibly, blocking the capillary with small piece of PVC. If difficulties are
encountered in making a connection, the end of the capillary can be tapered Page 14 or
alternatively, the bore of the PVC tubing can be increased by means
LMI/NPGC/CHEM/OGN/OPS/011 of a No.:
Revision hot wire.
0
Loosen the bottle top to permit air displacement and collect the required volume of
sample. DisconnectSampling of Steamand
the capillary and adjust
Water for
theChemical Monitoring
polythene bag and and Analysis
rubber band so
that the cap and sampling tube are protected against contamination, i.e. so that
contaminants cannot pass through the hold which has been punctured in the
polythene bag.
F) Sampling For Dissolved Gases
If water is passed through continuous lengths of metal or glass tubing, there should
be no errors in oxygen and carbon dioxide measurement from in-leakage of air from
the atmosphere. The main likelihood of contamination is where two pieces of rigid
tubing need to be joined by a flexible coupling, since unless the right connecting
material is used, permeation of air into the sample stream can occur. Thick-walled
neoprene tubing as a suitable coupling material, but even with this, it is advisable to
keep the length of tubing as short as possible and use it simply as a connecting
sleeve to make but joints, between the two sections of rigid tubing.
6.0 REVIEW :
HOD (O&M) will be responsible for reviewing the document every three years
basis or as necessary.
7.0 REVISION INDEX

(For change/ Revision)
Page 15
S. NO. Revision No. Date Details Approved by
NOTE: The LMI will be revised every 3 years.
8.0 DISTRIBUTION LIST
(i) HOP (NPGC) Through LAN
(ii) GM (O&M) Through LAN
(iii) HOD ( OPERATION)

Page 16

CALCULATION OF CAPILLARY LENGTH
Before an estimate can be made of the length of capillary to be installed, it is

necessary to calculate the mass floor rate delivered by the sampler under isokinetic
conditions. This is done by the following formula :
m/M = (d/D)2 xn
Where, m = sample mass flow rate
M = system mass flow rate
d = probe orifice diameter
D = pipe internal diameter
n = no. of orifices
With a knowledge of pressure at the main header and pressure drop (∆P) the length
of the capillary required can be calculated.
Pressure drop (∆P) across the capillary per meter the line length is calculated using
Darcy-Weishback formula as follows (Data’s are given on the next page)
(∆P) = fv2 / gd
= f(4Q/rid2)2 /2gd
= 8.271 x 10 -2 (fQ2/d5 (g = 9.8m/sec2)
= 2.647 x 10 –3 (Q2/ d5) (assuming f = 0.032
Thus, (∆P) = 2.647x103 (Q2/ d5) in meter of liquid column per unit
length of capillary.
Page 17

= 2.647x103 (Q2/ d5) in kg/cm2 if the liquid being sampled is

water at ambient temperature.
Where,( ∆P)= Pressure drop (kg/cm2) in meter of liquid column across

the capillary per meter length of capillary.
f = pipe friction factor determined from catalogues for

stainless steel
g = Acceleration due to gravity (m/sec2)
Q = flow of sample (m3 /sec)
D = Internal diameter (in meter) of capillary
v = velocity of fluid in the capillary in m/sec.

Page 18

EXAMPLE OF CALCULATION OF LENGTH OF CAPILLARY
Feed pipe internal diameter (D) = 305 m
Water flow rate (M) = 9740 kg/min at 70% MCR
Capillary internal diameter (d) = 0.51 mm
No. of orifices (n) = 1
Thus, we have,
m/M = (d/D)2 x n
Since the capillary is to be fixed to the main header, the capillary tip is to be bored
out to be 0.66 mm diameter.
Thus, we get
m/ 9740 = (0.66/305)2xl (Using d=0.66mm)
m = 0.0456 kg/min
= 7.6 x 10-7 m3/sec (taking density

of sampled water as 1000 Kg/m3)
Pressure drop per meter of capillary can be calculated as follows :
Q= m = 7.6x10-7 m3/sec
Page 19

∆P = 2.647 x 10-4 (Q2/d5)

= 2.647 x 10-4 (7.6x10-7 / 0.00051)5
= 4.43 kg/cm2 per meter of capillary
Since the main header pressure is 180 Kg/cm2, the theoretical length of capillary to
give a flow of 0.0456 kg/minutes shall be
180/4.43 = 40.63 meters
Because of variation in water temperature along the length of the capillary and
uncertainties in the variability of capillary bore and surface condition, it is necessary
to increase the length of installed capillary by 30% above the calculated figure.
Hence the length of the capillary to be installed will be 40.63 x,1.30
=52.82 meters.

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LMI/NPGC/CHEM/OGN/OPS/011

LOCAL MANAGEMENT INSTRUCTIONS

Sampling of Steam and Water for

TECHNICAL COMPLIANCE SYSTEM

Sampling of Steam and Water for

Approved for Implementation by CEO (NPGC)

PREPARED BY SIGNATURE: ………………………………….

CHECKED BY SIGNATURE: ……………………………………

REVIEWED BY SIGNATURE: ……………………………………

GENERAL MANAGER (O&M)

2.0 Superseded Documents 1

4.0 Reference Document 1

7.0 Revision Index 10

8.0 Distribution List 10

LMI/NPGC/CHEM/OGN/OPS/011 Revision No.: 0

SAMPLING OF STEAM AND WATER FOR CHEMICAL

2.0 SUPERSEDED DOCUMENTS :

The document provides guidance on various aspects relating to the conditioning of

4.0 REFERENCE DOCUMENT :

OPERATION GUIDANCE NOTE : COS-ISO-00-OGN/OPS/CHEM/011

LMI/NPGC/CHEM/OGN/OPS/011 Revision No.: 0

Issue No. 1 Dated August’1999.

a) ISO Kinetic Sampling

A device used to obtain a sample of water or steam, either discretely or

The precise position within a system from which a sample is taken.

LMI/NPGC/CHEM/OGN/OPS/011 Revision No.: 0

f) Sampling Delivery Point

5.2 SAMPLING EQUIPMENT – TERMINOLOGY

Historically, sampling equipment has fallen into two categories :

While “fast” sampling equipment is recognized as appropriate for the sampling of

LMI/NPGC/CHEM/OGN/OPS/011 Revision No.: 0

sampling of particulates, taking into account the desirability, firstly to simple

5.3 WATER SAMPLING

A pre-requisite of any sampling system is that it should extract a sample

LMI/NPGC/CHEM/OGN/OPS/011 Revision No.: 0

LMI/NPGC/CHEM/OGN/OPS/011 Revision No.: 0

A) Sampling soluble species

B) Sampling Particulate Species.

Representative sampling of particulates in water is important when analysing for

In some instances, a practical alternative to using capillary samplers is to use

LMI/NPGC/CHEM/OGN/OPS/011 Revision No.: 0

C) Positioning and Installation of Samplers

LMI/NPGC/CHEM/OGN/OPS/011 Revision No.: 0

c) Boiler Water Sampling

Boiler water sampling on some stations is achieved using a multi-tube sampling

5.4 STEAM SAMPLING

LMI/NPGC/CHEM/OGN/OPS/011 Revision No.: 0

B) Sampling Saturated Steam

C) Sampling Superheated Steam

LMI/NPGC/CHEM/OGN/OPS/011 Revision No.: 0

temperature of 20 deg C, a cooling water rise of 15 deg. C and counter current

5.5 USE OF CAPILLARIES FOR SAMPLING

B) Method of Preventing Blockage

Total blockage can best be prevented by ensuring that :

i) The sampling system is correctly installed with the

LMI/NPGC/CHEM/OGN/OPS/011 Revision No.: 0

5.6 SAMPLE ABSTRACTION FOR MANUAL ANALYSIS

B) Sample containers and storage

The determination of trace impurities in high purity water imposes stringent

LMI/NPGC/CHEM/OGN/OPS/011 Revision No.: 0

Sample bottle cleaning is essential to achieve reliable grab sample analysis. A

C) Sampling Line Purging before Sample Abstraction

D) Liquid Samples (Other than those taken from capillary lines)