SENTRY EQUIPMENT CORP The Sampling Connection Corrosion Products Sampler (CPS)

SENTRY EQUIPMENT CORPSENTRY EQUIPMENT CORPThe Sampling ConnectionThe Sampling Connection

Corrosion Products Sampler (CPS)Corrosion Products Sampler (CPS)


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)


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


CPS Flow DiagramCPS Flow Diagram


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


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


Sample Point SelectionSample Point Selection

Based on:Based on:System designSystem designSubject constituentsSubject constituents Chemical treatmentChemical treatment System specific problemsSystem specific problems


CorrosionCorrosion

Corrosion affects:Corrosion affects: Equipment reliabilityEquipment reliability Plant safetyPlant safety Efficiency and capacityEfficiency and capacity


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


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



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



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


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


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



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



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



Analyze filtered productsAnalyze filtered products Acid digestion + atomic absorptionAcid digestion + atomic absorption X-ray fluorescenceX-ray fluorescence

Calculate average concentrationsCalculate average concentrations


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


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


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


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


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


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


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)


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

SENTRY EQUIPMENT CORP The Sampling Connection Corrosion Products Sampler (CPS)

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