For various industrial processes with aggressive or otherwise particularly sensitive media, measuring pH, conductivity, or dissolved oxygen is not as easy as pulling measurements from the mainline. Some processes require a media sample to be extracted for treatment and conditioning before an accurate measurement can be made. This is the role of sample conditioning in the process industry.
What is Sample Conditioning?
Sample conditioning is crucial in many industries where precise measurements are essential for process control, quality assurance, and safety compliance. Additionally, proper conditioning helps in avoiding errors and protecting equipment. Conditioning also ensures that the data collected is representative of the actual process conditions. The goal is to ensure that the sample’s characteristics match the requirements of the measurement or analysis system, leading to accurate and reliable results. All of these factors contribute to maximum accuracy and maximum operational uptime.
Sample conditioning allows for operators to gain insight into a process using media samples that would otherwise over-encumber typical sensors. These factors range from temperature compensation and pressure & flow regulation to removing contaminating ions. Coolers, pressure reduction valves, and cation resin columns work in tandem to compensate for these factors. After operators condition the samples for these factors, they can accurately measure the process without risking damage to the measurement infrastructure.
Increasing Accuracy and Uptime with Sample Conditioning
Altering a sample’s temperature, pressure, and flow rate may be necessary to obtain a measurement that accurately reflects the condition of the process. Once a transmitter, such as the Stratos Multi, receives the measurement from the properly conditioned sample, necessary adjustments like caustic dosing can be factored into the mainline as the process progresses.
Temperature Moderation
Coolers like M4 Knick’s SC Sample Cooler ensure that samples are conditioned at a stable, controlled temperature, which is vital for accurate testing. Temperature adjustments also affect moisture content, sample stability, and the overall accuracy of testing. For some processes operating at extreme temperatures, a direct measurement taken without cooling could severely damage a pH sensor or other infrastructure. The SC Sample Cooler is equipped to handle most liquid, gas and steam processes.
Pressure Control
Pressure compensation is another critical aspect of sample conditioning. For a process operating at high rates of pressure, a direct measurement may be impossible due to the likelihood of fouling a sensor’s reference system. The design of the High Pressure (HPR) valve by M4 Knick is suitable for variable pressure drops and flow control of high-pressure liquid samples. Properly conditioning a sample for pressure helps ensure operators maximize the sensor’s accuracy and lifespan.
Flow Regulation
Flow regulation is essential for maintaining consistent and precise conditions during sample conditioning. Processes operating at high or inconsistent flow rates can cause complicating shifts in measurements once the media reaches a sensor. M4 Knick’s Back Pressure Relief (BPR) Valve regulates upstream pressure for analytical measurement. The BPR valve provides constant inlet pressure, allowing operators to shut off analyzers without varying the pressure and flow of the rest the analysis system.
Ionic Exchange
The M4 Knick CR cation resin columns are the ideal container for performing a cation exchange. Cationic resin columns remove cations in a sample through a dosing compound. This process is necessary to eliminate the masking effects of known chemicals such as ammonia or dissolved amines. In this exchange mechanism, the resin’s active sites exchange cations for H⁺ ions, which then pass into the sample stream. The columns have integrated retention filters on both the bottom and top of the device, retaining the resin in the column and allowing the sample to pass without affecting the exchange process.
Know Your Systems
Knowing your components can help to ensure that your samples are properly prepared and handled, which can improve the accuracy and reliability of your analytical results. M4 Knick is committed to providing maximum accuracy and maximum uptime for operators looking to enhance their process efficiency. Explore our sample conditioning components for more information on how you can optimize your analytics.
