Safe Design of Sampling Systems

Transcription

1 Safe Design of Sampling Systems Basic Regulations and Implementation of an Advanced Safety Concept Dr. Günter Schierjott, WösthoffMesstechnik GmbH Bernd Marx, Endress + Hauser Conducta GmbH Wösthoff Company Data Based in: Bochum, Germany Founded: th Generation family-run Business Areas: Sampling Systems Gas Mixing Systems Gas Analysers 1

2 Main Sampling Points 1 Boiler Drum 2 Feedwater Tank 3 CP 5 1. Feedwater 2. Boiler Water 3. Saturated Steam 4. Superheated Steam 5. Condensate 6. Reheated Steam 4 ST Condenser Guidelines and Directives PED 2014/68/EU - Pressure Equipment Directive DIN EN Water-tube boilers and auxiliary installations DIN EN Shell boilers VGB-S EN - Sampling and Physico- Chemical Monitoring of Water and Steam Cycles VGB-S-010-T-00; EN - Feed Water, Boiler Water and Steam Quality for Power Plants / Industrial Plants 2

3 Setup of Sampling Points Sampling Probe and System Shut-Off 2. Sample Blow-Off 3. Sample Shut-Off 4. Sample Cooling 5. Pressure Reduction 6. Temperature Protection 7. Pressure Control 6 7 Sample Distribution Main Sampling Components Shutt-off and Blow-Off Valves Sampling Coolers Regulating Valve Temperature Shut-Off Valve Overflow Valve Basic Requirements for all components: All wetted parts made of austenitic steel design temperature and pressure shall correspond to design values at the sampling point Valves and coolers must comply with PED 3

4 Pressure Equipment Directive Components covered by Pressure Equipment Directive: Sample coolers Shut-off valves Regulating valves Temperature shut-off valves Coolers and Valves are covered by paragraph 4.3 of PED Sound Engineering Practice No CE marking allowed Final inspection and testing required Marking according PED Pressure Equipment Directive Final inspection and test (100 %): visual inspection of equipment and documentation hydrostatic pressure test (1.5 x design pressure) test certificate (serial number, manufacturer, customer, material data) Marking of pressure equipment: manufacturer type designation serial number year built volume, nominal diameter design pressure, temperature fluid group 4

5 Wösthoff Safety Concept Basic safety provisions as defined in VGB-S-006 Advanced measures developed by Wösthoff to meet safety requirements of chemical industry Modular setup to be implemented in accordance with customers requirements Safety measures for cooling water compartments and sample lines Combination of safety components and intrinsically safe design Additional organizational measures Hazards of sampling systems Hazards: Cooling coil rupture Cooling water enclosed inside sample cooler Failure of the cooling water supply Possible Consequences: System pressure / vapor pressure inside the cooling water compartment High temperature in cooling water compartment Rupture of the cooling water compartment High temperature of sample led to analyzers, grab sampling High surface temperature of sampling lines 5

6 Safety Measures Cooling Water Cooling water check valve Corrugated pipe Flow indicator Cooling water thermometer Sample cooler - Material - Sealings Cooling water safety valve Passive Measures Cooling Water Component Measure Impact Passive measures: Cooler shell choice of material cooler withstands 3-fold cooling higher material thickness water design pressure Cooling water connections stainless steel corrugated pipe maximum pressure 5-fold cooling water design pressure thermally resistant to 200 C Sealings choice of material cesign of sealing surfaces thermally resistant to 200 C Cooling coil surface coating reduction of corrosion by highly chlorinated cooling water restrictor at the sample inlet reduction of sample flow in case of coil rupture Cooling water supply flow indicator indication of cooling water supply condition thermometer in cooling water return line indication if sufficient cooling water is supplied indication for cooling coil rupture 6

7 Active Measures Cooling Water Component Measure Impact Passive measures: Cooling water check integrated into cooling water cooling water compartment cannot valve return of each cooler be closed completely prevents pressure to rise above design pressure in case of cooling coil rupture, cooling water shut-off Cooling water safety valve installation acc. VGB-S on each sample cooler - on common cooling water return pipe Vapour barrier installation at the sample inlet of steam coolers to limit sample flow to 100 kg/h Temperature shut-off valve installation at the sample outlet of each cooler prevents pressure to rise above design pressure in case of cooling coil rupture, cooling water shut-off prevents excess pressure in cooling water compartment prevents steam to flow to cooling water compartment prevents cooling water from overheating prevents excess pressure in cooling water compartment Safety Measures Sample Cooling water check valve Corrugated pipe Steam barrier Flow indicator Cooling water thermometer Sample cooler - Material - Sealings Cooling water safety valve Protection against contact Temperature shut-off valve Cooling Coil - Restrictor at sample inlet - Material - Surface coating Pressure regulating valve 7

8 Passive Measures Sample Lines Component Measure Impact Passive measures: Cooling coil Material reduction of corrosion optimized lifetime surface coating reduction of corrosion by highly chlorinated cooling water restrictor at the sample inlet reduction of sample flow in case of coil rupture Hot surfaces, valves protection against accidental contact at T > 50 C prevents accidental contact minimizes risk of injury Active Measures Sample Lines Component Measure Impact Passive measures: Temperature shut-off installation at the sample outlet prevents cooling water from valve of each cooler overheating prevents excess pressure in cooling water compartment shut-down of sample flow at temperature > 50 C Protection of instruments from high temperature Protection of operators from high sample / surface temperature Pressure regulating valve Implementation in sample lines downstream sample cooler keeps sample pressure downstream cooler at 0,2 Mpa prevents excess pressure > 0,6 Mpa Protection of instruments from overpressure Protection of operators from overpressure 8

9 Organisational Measures Maintenance, Cleaning Any contamination of the sampling system shall be prevented by blowing off the sample lines before start-up If any contamination is inside the components the components shall be dismanteled and cleaned Depending on cooling water quality coolers shall be cleaned from deposit regularly All components shall be maintained according to manufacturer s manual Testing of main components All valves and measuring instruments shall be tested regularly Especially temperature shut-off valves shall be tested once a month as any contamination might keep the valves from closing Example for Sampling Systems 9

10 Data Management Safe Data Management : Reliable and accessible Sensor Data Planend maintenance Reliable Process Data Availability of Process and Sensor Data Availability of documentation Digitization and Industry 4.0 Digital Sensors can be maintained and adjusted under controlled conditions in laboratory to optimize their performance and lifetime Digital Sensors exchange in the process is quick and easy and this saves maintenance time Digital Sensor exchange in the field doesn t require experienced technicians Reliable Sensor Data Digital Memosens sensors Standard analog sensors 10

11 Accessible Sensor and Process Data Quality managemen t Information for Audit Maintenance workshop Sensor adjustments and managements Process management Management of sensors running in the process Central database Lab software gives you advanced sensor diagnostics Planed maintenance Improve process safety Ready for process Ready until next maintenance call Lab software (Memobase plus)controls sensor data and performance to editable customer limits Memobase Plus gives you clear guidance if a sensor needs additional maintenance or should be disposed 11

12 Multi access point: Web-App Plant control center Liquiline Control Platform Industrie 4.0 Added values FDM Software Memobase Plus MEMOSENS analysis Process maintenance forecast Process data & control Thank you for your Attention Germany (Headquarter): Heinrich Wösthoff Messtechnik GmbH Max-Greve-Strasse Bochum Germany Tel.: +49 (0) Mail: Sweden (Distribution): Endress + Hauser AB Sundbybergsvägen Solna Sweden Tel.: +46 (0) Mail: info@se.endress.com MATARVATTENKONFERENSEN 2015 Dr.-Ing. Phillip Schierjott 12