SAMPLING
PROCESS STREAM
Conveying
Distillation towers
Mixers
Pipes
Reactors
Storage vessels
Table 1 – Potential parameters for sampling
Below : Sentry ’ s Isolok SAK sampler
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Area classification
Composition
Corrosiveness
Flammability
Flow rate
Pressure
Radioactivity
Temperature
Toxicity
must be compatible with one another to avoid potentially unsafe scenarios , such as product contamination or equipment corrosion .
Prioritising operator safety
Beyond product quality and regulation compliance , implementing a sampling system that removes the operator from the process is critical to protecting personnel from hazardous situations .
Manual sampling methods like grab sampling do not protect operators from these situations and can expose them to potentially caustic or harmful chemicals in the process . Skin and respiratory exposure to chemicals used to develop these materials can leave operators at risk of burns , respiratory complications , rashes and even cancer .
Because of these serious risks , the speciality chemicals industry faces some of the most stringent safety standards and governmental regulations . For example , many operational environments must handle hazardous products or wastes such as hydrogen sulfide , sour gas or water , materials that are either explosive , toxic , abrasive , corrosive or a combination of some of those traits .
Process streams are maintained in many manufacturing plants or facilities
Gas
Liquid
Powder
Slurry
Solid
Steam
Water
MATERIAL CHARACTERISTICS
Abrasive
Boiling point
Density
Explosive
Freezing point
Hardness
Magnetic
Moisture content
Particle size & shape
Material compatibility
Thermal conductivity
at certain temperatures , pressures and flow rates . Therefore , it is essential to consider how the technicians will retrieve the sample ( pipes , tanks , mixers , conveying belts , chutes , towers , reactors or other equipment ) to develop the safest sampling method .
Closed-loop samplers are one of the best ways to ensure operator safety . They can fully contain liquids and gases to eliminate worker exposure to hazards , using a series of valves and vents for sampling control . There is the option to leverage sampling automation to reduce the need for human interaction . Overall , closed-loop samplers minimise the potential for contamination spills , stop the prolonged release of toxic vapours and reduce sample sizes .
Repair v . replacement
With ageing equipment and facilities , operators face increasing challenges in maintaining equipment ’ s reliability , integrity , and safety . One of the biggest hidden threats to a plant ’ s efficient and safe operation is deteriorating sampling equipment . However , knowing whether ageing equipment requires an update , repair or a complete replacement can take time and effort .
There are features designed to protect workers from these risks that do not necessarily require a total sampling system replacement . One is a spring return latch that automatically returns to a locked position . This ensures that hazardous materials are always closed off and are not creating a threat to the people around them .
While this system is not a standard in the industry yet , because of its preventative nature , more and more machines are encouraging the modification . Sentry has the ability to install the technology onto competitors ’ products . To make the repair v . replacement debate easier when it comes to ageing sampling equipment , it is essential to :
• Keep good maintenance programme records : These will help to track past incidents and repairs to determine whether future repair or replacement is a better decision
• Stay up-to-date on industry trends and sampling methods : This will ensure the equipment is never obsolete and has the latest functionality to deliver the precise measurements needed
• Maintain a strong sampling plan : Retrofits or replacements are not always necessary if you have a sampling plan that makes it easy to identify needs
• Pay attention to sampling systems : Sampling equipment and systems should be treated with the same importance as every other piece of equipment in the plant
Conclusion
The importance of a reliable representative sampling system to the safety of a speciality chemical plant cannot be overstated . With the correct maintenance and care , a quality system will help achieve production goals and meet regulations and guidelines while keeping both operators and the environment safe . To set a plant up for success , however , it is critical to put the time in to critically assess your sampling needs and communicate to design engineers the correct specifications to abide by . ●
Horacio Salinas
DIRECTOR OF BUSINESS DEVELOPMENT
SENTRY EQUIPMENT k + 1 713 258 9757 J horacio . salinas @ sentry-equip . com j www . sentry-equip . com
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