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Gas and Liquid Sampling Applications
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Applications Review Refinery Chemical Wastewater Mining Slurry
Pharmaceutical Plastics Milling and other
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Refinery Applications
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Refining An oil refinery is an industrial process plant where crude oil is processed and refined into useful petroleum products.
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Refinery Process
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Common Process Terms LSRG = light straight run gasoline
LAGO = light atmospheric gas oil HSRG = heavy straight run gasoline CVGO = combined vacuum gas oil LGO = light gas oil CGO = combined gas oil HGO = heavy gas oil DHGO = Desulfurized or distilled heavy gas oil KERO = kerosene DLGO = Desulfurized or distilled light gas oil CLAGO = combined light atmospheric gas oil
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Refinery Process Simplified
Separation Conversion Purification
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CDU – Crude Distillation Unit
CDU - an atmospheric pressure distillation tower. This unit accepts a variety of crude oils and distills them into the primary products including LPG, naphtha, kerosene, light gas oil and refined crude Heated crude condenses at various levels in the tower 250f 150 psig
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VDU – Vacuum Distillation Unit
VDU or vacuum distillation unit is a vacuum distillation tower. This unit accepts “reduced” crude processed by the CDUs and distills them into the primary products including LPG, naphtha, kerosene, light gas oil and refined crude 700 F typical 100 psig
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VBC – Visbreaking Unit VBC or Visbreaker is a thermal cracking unit. This unit accepts vacuum tower “resid” or the very viscous vacuum tower bottoms and uses high heat (800 F) to crack the hydrocarbons into fuel oil, naphtha and light gas oil 800 F typical 100 psig Typically a patented process (UOP, shell)
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HTU – Hydrotreater Unit
HTU or Hydrotreater uses a recycled hydrogen stream and catalyst to convert sulfur compounds to hydrogen sulfide, nitrogen to ammonia and aromatic hydrocarbons to stronger hydrocarbons. This unit accepts vacuum tower light and heavy gas oil and converts them to gasoline, kerosene and naphtha 200 F typical 200 PSIG liquids 1300 PSIG gases
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CRU – Catalytic Unit CRU or catalytic reforming unit removes oxygen, nitrogen and sulfur from naphtha that contaminates the unit’s catalyst and then converts it to gasoline Up to 500 F typical 200 PSIG liquids Typically a patented process (“Unifiner”, etc.)
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SRU – Sulfur Recovery Unit
SRU or sulfur recovery unit converts hydrogen sulfide into elemental sulfur Up to 200 F typical 100 PSIG liquids
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FCCU – Fluid Catalytic Cracking Unit
Fluid catalytic cracker (FCC) uses high temperature and catalyst to crack heavy gas oil mostly into gasoline. Hydrocracking uses catalysts to react gas oil and hydrogen under high pressure and high temperature to make both jet fuel and gasoline Up to 200 F typical 100 PSIG liquids
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Polymerization Unit Polymerization in the petroleum industry is the process of converting light olefin gases including ethylene, propylene, and butylene into hydrocarbons of higher molecular weight and higher octane number that can be used as gasoline blending stocks. Polymerization combines two or more identical olefin molecules to form a single molecule with the same elements in the same proportions as the original molecules. Polymerization may be accomplished thermally or in the presence of a catalyst at lower temperatures.
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Alkylation Unit Alkylation combines low-molecular-weight olefins (primarily a mixture of propylene and butylene) with isobutene in the presence of a catalyst, either sulfuric acid or hydrofluoric acid For fuels blending Various process methods
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Other Processing Units
Amine plant Amine removes sulfur and other impurities Hydrogen plant Recovers hydrogen from the processes and stores it along with additional H2 for hydrotreating LPG - liquid petroleum gas plant Recovers petroleum gas products, refines them and blends them for distribution as a liquid MTBE – methyl – tertiary- butyl- ether plant Generates MTBE from methanol and process gasses Used as a fuel additive
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Typical Sampling Points and Samples
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CDU – Crude Distillation Unit
Sample Name Sample Constituents Phase Temp (F) Pres. psig Recommend Sampler Problems/Concerns Observed Samples Desalter In Crude Oil Liquid 90 70 MVD Liquid Sampler Product waste, environmental, messy Desalter Out Desalted Crude Oil 200 to 250 Fumes from chemicals added to break the oil water emulsion (Betz W906), The Betz product requires PPE including respirator if the chemical is about 220 F. Cooler is inefficient and suffers from corrosion. Samples are sometimes hot. Desalter water Water, steam, oil Liquid/Vapor 200 130 Sample is too hot when a proper flow rate is attained; long sample line runs in 1” O.D. pipe LSRG Gasoline 150 Temperature, “representativeness” of sample, fumes HSRG
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CDU – Crude Distillation Unit
LGO Oil Liquid 150 MVD Liquid Sampler Temperature, “representativeness” of sample, fumes HGO KERO Kerosene Resid Out Bottoms Viscous Liquid 90 40-60 Fumes, mess Caustic Soda Caustic Soda in water 100 Hazardous, “representativeness” of sample
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VDU – Vacuum Distillation Unit
Sample Name Sample Constituents Phase Temp (F) Press. (psig) Recommended Sampler Problems/Concerns Observed Samples Gas Oil Oil Liquid 150 MVD Sampler Product waste, environmental, messy KERO Kerosene Temperature, “representativeness” of sample, fumes Blended Resid Oil, Vacuum tower bottoms 200 100 Heavy liquids sampler Sample is too hot when a proper flow rate is attained; long sample line runs in 1” O.D. pipe Vacuum tower bottoms Oil, tar 540 Sample is too hot when a proper flow rate is attained; long sample line runs in 1” O.D. pipe, location of sample point traps operator, splashes, drain plugging Sour Gas Oil Oil with H2S 708 46 Temperature, “representativeness” of sample
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VDU – Vacuum Distillation Unit
Boiler Blowdown Water Liquid 300 150 SL Panel Temperature, “representativeness” of sample, fumes HVGO Oil MVD Sampler Naphtha CLAGO Light Gas Oil CVGO Heavy Gas Oil LAGO Sour Water Water + H2S 125 60 Temperature, “representativeness” of sample, H2S fumes Resid Out Bottoms Viscous Liquid 90 40-60 Heavy liquid sampler Fumes, mess
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VDU- Visbreaker Sample Name Sample Constituents Phase Temp (F)
Press. (psig) Recommend Sampler Problems/Concerns Observed Samples Visbreaker bottoms Oil, tar Liquid 460 100 Heavy liquid sampler Sample is too hot when a proper flow rate is attained; long sample line runs in 1” O.D. pipe, location of sample point traps operator, splashes, drain plugging Visbreaker off gas Hydrocarbon gas + H2S Gas 40 MCL/MCG sampler “representativeness” of sample, fumes, difficult sample to obtain LVGO Light Gas Oil MVD Liquids sampler Temperature, “representativeness” of sample, fumes CVGO Heavy Gas Oil 250
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HTU- Hydrotreater Sample Name Sample Constituents Phase Temp (F)
Press. (psig) Recommended Sampler Problems/Concerns Observed Samples KERO Kerosene Liquid 80 MVD Liquid Sampler Temperature, “representativeness” of sample, fumes Naphtha DCGO Gas Oil 50 DHGO Heavy Gas Oil 200 180 DLGO Light Gas Oil Temperature, “representativeness” of sample, Hydrogen H2 Gas Ambient 1300 MCL/MCG sampler Pressure, “representativeness” of sample, explosive Recycled Process Gas H2 + H2S 1200 RX Effluent Oil + Gas + H2S Multi-phase 100 Pressure, “representativeness” of sample, fumes Refractionater Off Gas CH4 6 Pressure, “representativeness” of sample, flammable Charge LVGO + HVGO Condensate Water Temperature, “representativeness” of sample
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SRU – Sulfur Recovery Unit
Sample Name Sample Constituents Phase Temp (F) Press. (psig) Recommended Sampler Problems/Concerns Observed Samples Sour Gas H2S Gas 15 MCL/MCG Sampler Temperature, “representativeness” of sample, fumes, ammonia salts Amine Acid Gas Amine Gas 200 Hydrogen Sulfide 150 MCL/MCG Sampler/Drager tube sampler “Representativeness” of sample, fumes Condensate Water Liquid 100 MVD Liquid Sampler Temperature, “representativeness” of sample
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CRU – Catalytic Reformer Unit
Sample Name Sample Constituents Phase Temp (F) Press. (psig) Recommended Sampler Problems/Concerns Observed Samples *Unifiner Bottoms Aromatics, Paraffins, Naphins, Olefins Liquid 210 140 Heavy liquid sampler, ISOLOK® Temperature, “representativeness” of sample, fumes, waste (6-8 liters per sample) Unifiner Charge Kero or Oil Gas 100 500 MVD liquid sampler High pressure, poor location Unifiner charge Naphtha Unifiner stripper bottoms Unifiner stripper off gas Hydrocarbon gas + H2 Gas 380 MCL/MCG Sampler Representativeness” of sample, explosive, waste Platformer Recycle Gas 70% H2
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LPG – Liquid Petroleum Gas Unit
Sample Name Sample Constituents Phase Temp (F) Press. (psig) Recommended Sampler Problems/Concerns Observed Samples Depropanizer Tops Hydrocarbon gas + H2S Gas Unk MCL/MCG Sampler Hazardous, representative Depropanizer Bottoms Caustic Soda Sodium Hydroxide Liquid MVD Liquid sampler Depropanizer Off gas Deethanizer off gas Condensate Water SL Panel
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Amine Units Sample Name Sample Constituents Phase Temp (F)
Press. (psig) Recommended Sampler Problems/Concerns Observed Samples Lean Amine DEA, H2S Liquid Unk MVD Liquid Sampler Representativeness” of sample, health risk Rich Amine Regen Reflux
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Simplified Refinery Process
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Other Processing Units
Hydrogen plant MCL/MCG sampler LPG - liquid petroleum gas plant MCL/MCG sampler with outage volume MTBE – methyl – tertiary- butyl- ether plant MVD sampler Marine terminals ISOLOK® Tank farms Back purge tank sampler
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Reasons Refineries Sample
Confirm unit operation Quality control and custody transfer between units and customers Environmental control and compliance Process control (catalyst, heat exchanger, unit performance) “did I remove enough sulfur?” “Did I get enough C & H out?” Waste water treatment loading
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Keys to Refinery Sampling
Speed loop Open Cooling (60 C C) Pressure reduction
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Typical Materials Sampled
Refinery Petrochemical/Chemical Cracked Gases Aromatics Liquids Products Organics Plastics Inorganics Fuels Acetylene Benzene Paraffins Gasoline Acids Monomers Nitric Acid Propylene Toluene Naphthalene Kerosene Alcohols Solvents BTX Butane Xylenes Gas-Oils Oils Aldehydes Bottoms Amines Glycols Ketones Phenols
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Keys to Refinery Samples
Speed loop Open Cooling (60 °C – 149 °C) Pressure reduction
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Chemicals/Petrochemicals
Acetic Anhydride Methanol feedstock Used to make cellulose acetate and plastics Aspirin & pharmaceuticals Hazardous to breathe and skin contact Corrosive MVD, MFV, MIL
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Chemicals/Petrochemicals
Methanol Feedstock is coal and natural gas Used to make acrylic polymers and solvents MVD, MCG
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Chemicals/Petrochemicals
Acetic acid Base for aldehydes Primary production in Asia is for use in composite wood adhesives and other adhesives MVD, MIL, MFV
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Chemicals/Petrochemicals
Monostyrene Plastics MFV, MVD
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Chemicals/Petrochemicals
PX (Paraxylene) Feedstock is refinery reformate gases Benzene Primary use: Polyester MFV, MVD, MCG
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Why Use Sentry Samplers?
Operator safety Environmental safety Sample is representative of the process Easy operation Low maintenance Eliminates spills
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Industry Trends Government low sulfur fuels rules – now and on-going
North America Government low sulfur fuels rules – now and on-going Local environmental and emission requirements – California (bay area air quality management district) International Want to meet north America’s rules to sell to market All Crude is increasingly sour (high in sulfur) Crude is increasingly harder and more expensive to get See above New processes are being developed to meet the new low sulfur requirements and to make sulfur removal more efficient Fuel blending
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MVD Sampler With Box and Heater
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MVD Sampler With Sample Cooler
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MFV Sampler
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MCL Sampler
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MCG Sampler for Gases
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Wastewater Applications
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Wastewater – Process flow
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Typical Sampling Points
Outlet of settling tank Solids outlet of clarifier Outlet of digester
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Why Sample in a Wastewater Plant?
Control solids ratios at the digesters 70% of plant costs deal with the removal of solids Digesting sludge reduces solids volumes thus, less to incinerate Improve overall plant efficiency Cost control Truck load out verification Hauling costs are based on lbs of liquid Control the concentration of solids
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Challenges With Sampling in a Wastewater Plant
Stinky and sloppy job Spigot under pressure = VERY MESSY! Manual samples are not representative due to human variances and operators attempt to reduce messes Dozens of sampling points result in high labor costs and inaccuracies (due to inconsistent composite samples) Ergonomics (the ideal sample point is not always located in an easily reachable location)
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Why the ISOLOK®? ISOLOK® is the only sampler that can effectively sample sludge from a pressurized line Automatically captures fixed sample volume at fixed time intervals providing uniformity and consistency of sample for process control (elimination of human error) Unit is simple, safe, and reliable Clean (eliminates material spillage) VERY low labor costs Each MANUAL grab sample typically takes 10 minutes (including clean up) every couple of hours Sampling with the ISOLOK® typically only requires operators to collect the containers ONCE per day!
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Mining Slurry Abrasive
Corrosive due to acids, bases used to extract minerals Particle size
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ISOLOK® in Shell Oil Sands
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Pharmaceutical Applications
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Typical Pharmaceutical Process Flow
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Typical Pharmaceutical Process Flow
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Typical Pharmaceutical Process Flow
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Typical Sampling Points in a Pharmaceutical Plant
Reactor vessels – Top Reactor Sampler Pipes/tanks – MBP Tank farms Process piping Solvent recovery - MVD
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Reactor Vessel Sampling
ISOLOK® Top reactor sampler Back purge tank sampler HPI sampler
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Reactor Vessel Sampling
ISOLOK® Top reactor sampler Back purge tank sampler HPI sampler
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Reactor Vessel Sampling
ISOLOK® Top reactor sampler Back purge tank sampler HPI sampler
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Reactor Vessel Sampling
ISOLOK® Top reactor sampler Back purge tank sampler HPI sampler
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Pipe / Tank Sampling Incoming raw material at truck unloading station
Generally sample for custody transfer reasons Tank farm Sampling of individual ingredients prior to transfer to the make tank Process piping Quality control checkpoints along the process
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Pipe / Tank Sampling
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Pipe / Tank Sampling
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Solvent Recovery
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Why Sample in a Pharmaceutical Plant?
Custody transfer Process control Chemical analysis
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Challenges With Sampling in a Pharmaceutical Plant
Obtaining a representative sample from a lined reactor with high process temperature and pressure / vacuum Extracting sample from a device with a moving agitator Often requires special materials of construction Hastelloy, titanium, AL6XN, etc Many sample points require “closed” sampling to eliminate operator exposure to hazardous conditions
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Why Sentry Samplers? Wide variety of materials of construction available to satisfy process conditions Special alloys Seal materials Ability to offer closed sampling solutions when required Needle/septum samplers ISOLOK®® - exchanged air is returned to process through sample annulus
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Plastics Applications
Liquid Resin
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Liquid Resin High performance liquid resin is used in such things as bowling balls, boat hulls, etc.
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Challenges With Sampling in a Plastics Plant?
Pressure or vacuum isolation Viscosity Carry over Sample port/valve plugging Temperature During and after sample
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Typical Sample Point Sample from a jacketed reactor
Sample point is located in a recirculation/speed loop Sample must remain hot to avoid setting
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Liquid Resin Sampler is located in an enclosure and is heat jacketed
Sample drops into a container and is allowed to cool and set Customer takes the sample back to lab and re-melts for analysis
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Why the ISOLOK®? Ability to handle high viscosity fluids
Easily heat jacketed Can withstand high pressures and temperatures while isolating the process and environment from each other Automatically takes fixed volume of material at fixed time intervals Simple, safe, and reliable Clean (eliminates material spillage) VERY low labor costs Provides accurate verification for plant control
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Milling and other Applications
High fructose syrups (corn, beet) Soy oil refining process Byproduct streams Process waste streams
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Why Sample in Milling Processes?
Quality Assurance Custody transfer Process control Effluent discharge regulations
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Why Sample in Milling Processes?
3-A Designated Samplers M4KSA MSA MSD MSC MSE FDA Components; Seals and materials
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Challenges With Sampling - Milling Processes
Process flow volume can vary so sampling frequency must vary accordingly Process chemicals require exotic materials for wetted components Manual samples are not representative due to human variances and operators attempt to reduce messes Dozens of sampling points result in high labor costs and inaccuracies (due to inconsistent composite samples) Ergonomics (not always feasible to sample proportionally with the operation of other process equipment)
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Why the ISOLOK®? Simple, safe, and reliable
Uniformity and consistency of sample Elimination of human error Clean (eliminates material spillage) Can be controlled to proportionally operate with other process equipment Provides accurate verification for plant and governmental control
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Dairy Applications
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Typical Sampling Points in Dairy Application
Raw milk receiving at truck unloading dock Close to milk pump discharge
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Why Sample in Dairy Applications?
Payment calculation for farmer Butter fat content Protein Other solids Bacteria level Hormone levels (BGH) Antibiotics
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Challenges With Sampling in Dairy Applications
Equipment must be 3-A compliant (Section of 3-A code) Must be easily removed and cleaned without the use of tools Sample should be taken proportional to flow rate to ensure sample is representative of the entire truckload May require sampler to turn on/off with milk pump
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Why the ISOLOK®? Sentry is the only U.S. Based manufacturer with section A approval (Model M4-KSA and MSA samplers) Unit can be easily removed and cleaned without the use of tools Sampler automatically takes small fixed volume per stroke (typically 3cc) frequently throughout the entire truck unload process to ensure sample composite is representative of the entire truckload
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Dairy Applications
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Questions?
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