ON-LINE ANALYSER
PRESENTATION
1
Uses of Analysers
Type of Analysers
Operating Principles
Analyser Systems
2
Topics to be covered
WHAT IS AN ANALYSER ?
3
A DEVICE THAT MEASURES AND TRANSMIT INFORMATION
ABOUT CHEMICAL COMPOSITION , PHYSICAL PROPERTIES
OR CHEMICAL PROPERTIES OF THE SAMPLE IS KNOWN AS
AN ANALYSER
4 TYPE OF ANALYSERS
OFF-LINE or LAB ANALYSERS
ON-LINE or PROCESS ANALYSERS
USE OF On-LINE ANALYSER
5
ON LINE ANALYSERS ARE USED TO MONITOR & CONTROL
PRODUCT QUALITY - RAW / INTERMEDIATE / FINAL
ENERGY CONSERVATION- STACK
ENVIRONMENTAL CONTROL - STACK
REACTION or CORROSION CONTROL
OPERATING MANPOWER - REDUCING LAB LOAD / MANPOWER
PRODUCT or QUALITY CONTROL
6
FRACTIONATOR OR DISTILLATION COLUMN
CONTROL
HERE ANALYSER SYSTEMS CAN IMPROVE
PRODUCT QUALITY , INCREASE THE YIELDS OF
PRODUCTS WITH HIGHER ECONOMIC VALUES ,
REDUCE ENERGY COSTS.
ANALYSER MAY BE USED EITHER IN
DETERMINING IMPURITY OF HEAVIER
COMPONENTS IN LIGHT DISTILLATE PRODUCT
OR LIGHTER COMPONENTS IN HEAVIER PRODUCT
F F
F
A
8 BLENDING CONTROL
MAIN OBJECTIVE OF BLENDING
TO PRODUCE PRODUCT TO THE
SPECIFICATION
USE MORE OF LOW COST PRODUCT
REDUCE WASTAGE OR PRODUCT
GIVE-AWAY OF HIGH VALUE PRODUCT
A
A F
BLEND HEADER
PHYSICAL PROPERTY
F ANALYSERS LIKE FLASHPOINT ,
A DISTILLATION , POURPOINT ETC
ARE USED TO MEASURE THE
REQUIRED PHYSICAL PROPERTY
OF THE SAMPLE & CONTROL
A F BLENDING
A F
10 FIRED HEATER or BOILER COMBUSTION
EFFICIENCY CONTROL
USED IN FIRED HEATERS TO CONTROL
COMBUSTION EFFIENCY BY CONTROLLING
UNBURNT FUEL
ACHIEVING PROPER AIR FUEL MIXTURE
A
O2/CO ANALYSERS ARE USED AS
COMBUSTION MOINTORING
ANALYSERS IN FLUE GASES IN
HEATERS .
HEATER
F F
FUEL AIR
12 ENVIRONMENTAL CONTROL
TO SATISFY ENVIRONMENTAL LAWS ANALYSERS ARE
REQUIRED TO ANALYSE, REPORT & LOG AMBIENT AIR
QUALITY AND MONITOR RELEASE OF GASES TO
ATMOSPHERE OF HAZARDOUS CHEMICALS
SOX/NOX / CO ANALYSERS ARE USED AS EMMISSION
MONITORING ANALYSERS TO CHECK THE COMPLIANCE
OF THE EMMISSIONS WITH THE POLUTION CONTROL
NORMS SET BY THE GOVT.
OIL-IN WATER or TOTAL ORGANIC CARBON
ANALYSERS ARE USED IN E.T.P. FOR TESTING
POLLUTION IN WATER DISCHARGED
13 REACTION OR CORROSION CONTROL
ANALYSERS ARE REQUIRED FOR STEAM AND
WATER ANALYSIS TO REDUCE COROSSION BY
MEASURING PARAMETERS LIKE
pH. ( Acidity )
CONDUCTIVITY
SILICA
DISSOLVED OXYGEN
OIL IN WATER
14
PHYSICAL PROPERTY ANALYSERS LIKE FLASHPOINT ,
DISTILLATION , POURPOINT ETC ARE USED TO MEASURE A
PARTICULAR PHYSICAL PROPERTY OF THE SAMPLE
O2/CO ANALYSERS ARE USED AS COMBUSTION MOINTORING
ANALYSERS IN FLUE GASES IN HEATERS .
HYDROGENANALYSER APPLICATIONS
ANALYSERS ARE USED TO MEASURE THE PURITY
OF HYDROGEN IN RECYCLE GAS COMPRESSORS
ANALYSER APPLICATIONS
15
GAS CHROMATOGRAPHS ARE USED ARE USED TO ANALYSE
THE PRODUCT QUALITY AND FOR PROCESS CONTROL AND
OPTIMIZATION.
pH, CONDUCTIVITY, DO2, OIL IN WATER
ANALYSERS ARE USED IN WATER QUALITY ,STEAM
CONDENSATE ANALYSIS.
MOISTURE ANALYSER IS USED TO ANALYSE THE
MOISTURE CONTENT IN DRIED GASES LIKE
PROPYLENE AFTER DRYER.
WATER IN OIL ANALYSER IS USED TO ANALYSE
THE AMOUNT OF WATER PRESENT IN THE OIL
Analysers are classified as following
Direct Measurement
Predictive Analysers
TYEPES OF
16
ANALYSERS
VARIOUS
17
TYPES OF ANALYSERS
FLASHPOINT SULHUR IN LIQUID
POURPOINT pH
DISTILLATION CONDUCTIVITY
OPACITY DISSOLVED O2
HYDROGEN NIR
O2/CO NMR
O2/CO2 GAS CHROMATOGRAPHS
SOX/ NOX/ CO MOISTURE
WATER IN OIL VISCOSITY
DENSITY SILICA
OIL IN WATER
18 Direct Measurement
These analysers will be further classified as following
Gas Analysers
e.g. H2, N2, CO, CO2, O2 etc
Stack Analysers
e.g Smoke Opacity, O2, CO2, S0x N0x
SWAS ( Steam and Water Analysis System )
e.g. pH, Conductivity, Silica, Dissolved Oxygen etc
Quality Measurement
e.g. G.C.
Physical Properties
e.g. Viscosity, Flash Point, Pour Point, etc
19 Predictive Analysers
They are mainly of following 2 types
NIR
NMR
20 Principle of Measurement
Gas Analysers
Hydrogen
Measured by a Thermal Conductivity Cell.
The cell consists of a WHEATSTONE Bridge where
sample is passed over one arm of the cell and the
other arm is kept in Reference Gas ( AIR). This
causes an imbalance of the bridge which is directly
proportional to the Hydrogen Concentration
21 Principle of Measurement
Non-Dispersive Infra Red Analyser for measurement of Various Di-
atomic Gases like S0x N0x CO CO2 etc
A heated tugesten filament lamp is used as IR Souce
which focuses IR beam, through a filter alternately
through a Sample Cell and reference cell ( which
contains N2 ) towards a detector. The variation in
pressure in the detector due to heating by IR beam is
directly proportional to the Concentration of the Gas.
NDIR DETECTOR OPERATING PRINCIPLE
SAM PLE IN
SAM PLE
O PTICAL O UT CAPACITANCE
CHO PPER FILTER TYPE DETECTO R
W HEEL W HEEL DIAPHRAG M
SAM PLE.SIDE
SAM PLE SIDE
PRE
AM P
BOARD
REFERENCE SIDE ( AIR )
IR REF.SIDE
SO URCE
SAM PLE CUVETTE N O T E : T H E R E A D IN G O N T H E D IS P LA Y
UPDATES EVERY 5 SECS.
CHO PPER
M O TO R FILTER W AVE LENG THS USED IN
M AIHAK:-
SO2:- 6.850 um
SO2 NO
NO:- 5.3 um
CO:- 4.64 um
CO CO
LUFT DETECTOR D E P T :- C E S -IN S T
NO SO2
LUFT
M A D E B Y:- DETECTOR
N IR A V .A .B A X I
CHOPPER W HEEL O P T IC A L F ILT E R 01
D W G N O :-
W HEEL
D A T E ;- 4/06/01
23 Principle of Measurement
Oxygen is measured by mainly following 2 principles
Paramagnectic cell
for measurement of Oxygen in process gases
Zirconia Oxygen cell
for measurement of Oxygen in flue gases of Fired Heater stack
24 Principle of Measurement
Paramagnectic Oxygen Analyser
A quartz dumb-bell containing N2 is placed in a
non-uniform magnectic field. The
paramagnectic property of Oxygen in the
sample causes the dumb-bell to rotate. The
degree of rotation is directly proportional to
the Concentration of Oxygen
Mirror
Sample
Flow
Detector
Dumb-bell
Magnet
26 Principle of Measurement
Zirconia Oxygen Analyser
Zirconia is sandwiched between two chemically inert platinum electrodes and
Sample Gas is passed through one side while reference gas through other
side. When this is heated to a temperature of about 600 deg C a potential is
developed across the electrodes as per Nernest equation
WHERE
E= Volatge
R= UNIVERSAL GAS CONSTANT
T= ABSOLUTE TEMPERATURE
F= FARADAY’s CONSTANT
P1= PARTIAL PRESSURE OF OXYGEN IN SAMPLE
P2= PARTIAL PRESSURE OF OXYGEN IN REFERENCE
Reference Gas O2
Potential E
Inner Electrode
Outer Electrode
Sample Gas
28 Principle of Measurement
Gas Chromatograph
What is Chromatography
It is the method of separation of components in sample being analyzed
by bringing two immiscible phases ; one mobile and one stationary in
contact with each other
Carrier
(Mobile Integrator /
Phase) Recorder /
Computer
Sample
Detector
Column
Chromatography
Gas High Performance Liquid
Chromatography Chrmatography
Gas Liquid Partition
Chromatography Chromatography
Adsorption
Chromatography
Gas Solid
Chromatography Ion Exchange
Chromatography
Gel Permeation
Chromatography
Overview of Gas Chromatograph
Supply of Sample Column Detector Integrator / Oven
carrier Gas Injection Recorder /
System Computer
Thermal Conductivity
Detector
TCD
Hydrogen Packed for measurement of sample in
percentage levels
FID FID
Flame Ionisation Detector
for measurement of sample in
Nitrogen Capillary ppm levels
FPD
FPD
Flame Photometric Detector
For measurement of Sulphur
based compounds
Helium
SAMPLE INJECTION
Column
Detector
Carrier
Sample In
Sample
Sample Out Loop
Column
Detector
Carrier
Sample In
Sample
Sample Out Loop
PARTITIONING THEORETICAL PLATES
TI Column divided in to theoretical plates.
TIME 2
Theoretical Plates Colu
mn
Wall
Time1 Mobile Phase
HETP(mm) Liquid Phase
TIME 3
Time2
Time3
CHROMATOGRAM
RT1 RT2
TIME
34 Principle of Measurement
pH Analyser
pH IS DEFINED AS THE NEGATIVE ALGORITHM OF THE HYDROGEN ION
ACTIVITY. IT IS A MEASURE OF THE ACIDITY OR ALKALINITY OF A
SOLUTION.
pH = -LOG [ H+ ]
COMBINATION ELECTRODE IS THE MOST COMMONLY USED ELECTRODE
IN THE INDUSTRY.
IT CONSISTS OF A pH ( GLASS ) ELECTRODE AND A REFERENCE ELECTRODE
TOGETHER IN ONE UNIT. USUALLY THE pH ELECTRODE ( WHICH IS
SEALED ) FORMS THE CENTRAL PART OF THE ELECTRODE AND THE
REFERENCE ELECTRODE SURROUNDS THE MEASURING ELECTRODE. THE
REFERENCE ELECTRODE STILL HAS A POROUS OR FIBRE PLUG WHICH IS
ESSENTIAL FOR CONTACT WITH THE SOLUTION BEING MEASURED.
35 Principle of Measurement
Conductivity Analyser
PRINCIPLE OF MEASUREMENT: THE CONDUCTIVITY OF
A SAMPLE IS A MEASURE OF THE CONCENTRATION OF
THE VARIOUS CHARGED IONS IN IT. AS THE
CONCENTRATION OF SUCH IONS INCREASES, THE
CONDUCTIVITY INCREASES.
CONDUCTIVITY = CONDUCTANCE X CELL
CONSTANT
36 Principle of Measurement
Physical Properties Analysers
Viscosity Analyser
The differential pressure across a capillary is measured for
fixed flow which is directly proportional to Viscosity
Flash Point
The sample is slowly heated and the enclosed vapours are
continously sparked. The temperature at which flash
occurs is the Flash Point
37 Principle of Measurement
Predictive Analysers
A spectra of the sample is collected and simultaneously sample is analysed in lab
for the properties to be measured. This procedure is followed for building a
database of lab result and Analyser Spectra. Once sufficient spectras are
collected Chemeometrics is used to build a mathematical model which is
loaded into the analyser computer.
The Analyser then predicts the result by generating a spectrum and using The
mathematical Model
38 Principle of Measurement
Main Advantage of Predictive Analysers
Many properties can be had from a single analysers
thereby leading to a large saving in Capital as well as
operational expenditure
Disadvantage
Requires a long start-up time for building the models
Required regular model validation to check for accuracy
of prediction
Changes in Plant process characteristic will require model
changes
39 ANALYSER SYSTEM
THE ANALYSER SYSTEM CONSISTS OF THE FOLLOWING ELEMENTS
SAMPLE PROBE
SAMPLE CONDITIONING SYSTEM
ANALYSER
ANALYSER HOUSE
ANALYSER SYSTEM FLOW DIAGRAM
40
SAMPLING PROBE
41
SAMPLE CONDITIONING SYSTEM
42
THE GENERAL FUNCTIONS OF THE SAMPLE CONDITIONING SYSTEM
ARE:-
CLEANING OF THE SAMPLE
MINIMIZING THE TIME LAG IN GETTING THE SAMPLE TO THE ANALYSER
MEETING THE PRESSURE , TEMPERATURE , AND SAMPLE FLOWRATE
REQUIREMENTS OF THE ANALYSER
SAMPLE CONDITIONING SYSTEM
43
MEETING SPECIAL REQUIREMENTS OF THE ANALYSER
SUCH AS VAPORISING A LIQUID SAMPLE , REMOVING
WATER DROPS ETC.
DISPOSITION OF THE SAMPLE
ANALYSER HOUSE
44
THE ANALYSER HOUSING IS REQUIED :
TO PROVIDE A TEMPERATURE CONTROLLED ENCLOSURE
TO PROTECT THE ANALYSERS FROM ENVIRONMENT VAGARIES
Features of Analyser House
45
The desirable features of Analyser Houses are
50 mm Rockwool insulation between two SS plates
2 HVAC’s with one on Automatic stand-by
12 Volume changes with fresh air via a fresh air duct
Positive pressure inside the House to prevent ingress of flamable gases into the house
46 Features of Analyser House
Fire, Gas and Toxic sensors connected to a safe-guarding system
Alarms to Plant Fire & Gas System
2 Self closing door with panic bars
Proper lighting both inside and outside with at least one battery back-up
light inside the house
Isolation of Flammable materials inside House in case of emergency.
47 Features of Analyser House
Analysers mounted along the wall of the house
Sample-conditioning system mounted outside the house
Excess flow check valves in lines going into the house
