Modular Sampling/Sensor Array For Water Quality Monitoring David M. Simko Swagelok Company IFPAC SM 2004 Arlington, Virginia January 12-15, 2004

Water – The Essential Fluid For: Municipal, residential, commercial, institutional, industrial Focus on industrial: Chemical, petrochemical, refining, pulp and paper, power, food and beverage, pharmaceutical, and semiconductor manufacturing Water can be used as a utility, a reactant, or a raw material

Water Quality – Primary Measurements General qualitative description of water Color, odor, taste, clarity Quantitative measurements of water quality pH – hydrogen ion concentration ORP – oxidation-reduction potential Conductivity – total ionic concentration Dissolved oxygen – specific applications Other

Water Use - Chemical/Petrochemical Heat transfer medium – condensers, heat exchangers, cooling towers, etc. Raw material – diluent Solvent – washing product/equipment Reactant – (Ex.) producing high-purity hydrogen in a steam reformer PRIMARY QUALITY CONSIDERATION: CORROSION RESISTANCE

Water Use – Refining Water is used in almost every refining process from alkylation through visbreaking As much as 77,000 gallons/100 barrels of crude Primary heat transfer medium PRIMARY QUALITY CONSIDERATION: CORROSION CONTROL

Water Use – Pulp and Paper Water flows within every line in the utilities, pulping operations, and on the paper making machine Water usage 7,920 gallons/ton of pulp – mechanical pulping 39,600 gallons/ton of pulp – chemical pulping Applications Cooking pulp, drying paper, cooling PRIMARY QUALITY CONSIDERATION: CORROSION, SCALE, AND BIOLOGICAL CONTROL

Water Use – Power Generation Treated water is the process fluid in a power plant Conductivity – measured at all key points pH – measurement focused in the steam area DO – measured around the deaerator Usage depends upon the size and design of the power plant PRIMARY QUALITY CONSIDERATION: CORROSION AND SCALE CONTROL

Water Use – Food and Beverage Food and beverage processing are sanitary industries Typical annual US consumption Beer – 6.2 billion gallons Carbonated soft drinks – 15.2 billion gallons Water – 6.3 billion gallons Water is the primary raw material PRIMARY QUALITY CONSIDERATION: CHEMICAL/ BIOLOGICAL CONTAMINATION

Water Use - Pharmaceutical Water is the most widely used raw material in the pharmaceutical industry Pharmaceutical grade waters Potable, purified, WFI, reageant Utility grade waters Plant and clean steam, chilled water PRIMARY QUALITY CONSIDERATION: APPLICATION SPECIFIC CHEMICAL, MICROBIAL, AND PHYSICAL ATTRIBUTES

Water Use – Semiconductor Mfg. Requires the highest purity water attainable, in large amounts Example: For a reasonable size integrated facility Make-up – 450 gallons/minute Reclaim – 250 gallons/minute PRIMARY QUALITY CONSIDERATION: PARTICULATE, DISSOLVED CHEMICALS

Water Quality – Measurement Tools pH, ORP, Conductivity, DO Probe, electrodes based upon potentiometric methods Numerous manufacturers/suppliers (Sensors Magazine Buyers Guide pH- 79 ORP- 55 Conductivity- 86 Dissolved oxygen- 70 Many offer all or several of the devices

Water Quality – Measurement Tools Devices must be adapted to meet ANSI/ISA Most manufacturers offer inline mounting provisions for their devices, many times a bore-through Swagelok tube fitting Substrate manufacturers must work with the device manufacturers to make adapter/NeSSI in-line mounting provisions available

Water Quality – Sensor Platform – c.2000

Water Quality – Sensor Platform – c.2004