Process Monitoring: What Really Matters
Process Monitoring: What Really Matters
and flow meter. Resin exhaustion is calculated from the
Ruedi Germann sample flow and the differential conductivity.
Sample Temperature
ABSTRACT It is amazing to see how much money designers designate
to tight temperature control with numerous coolers.
This paper focuses on an increasingly important topic:
Modern instruments, however, can compensate for
problems with bidding procedures for process moni-
changes in sample temperature in a wide range. With the
toring instrumentation. The recent calls for bids are
use of solution temperature compensation it is sufficient to
exclusively focussed on prices and do not take into
maintain a sample temperature below 45 °C. Money spent
account the kind of application and the specific requi-
on coolers would be better invested in securing steady
rements with respect to instrument maintenance and
sample flow.
quality assurance. As a rule, the cheapest instrument
selected does not in the majority of cases represent
the best solution, in particular for cycle chemistry
monitoring in power plants.
GOOD INSTRUMENT CHOICE
Technical specifications in bidding documents often do
not include the measuring point and the nature of the sam-
INTRODUCTION ple. Internet bidding for several power plants was recently
conducted for 150 conductivity meters, 30 pH meters and
Analytical instruments for process monitoring have
8 dissolved oxygen meters without further details. The
evolved considerably over the last decades. The focus on
operator might get a good price, but the instrument might
electronic stability and sensor accuracy has shifted to an
be more suitable for potable water than for steam and
emphasis on cost of ownership and quality assurance. The
condensate. Everyone has the instruments he deserves.
log files of the support department of an instrument man-
ufacturer clearly indicate that the practical problems lie in
sampling, in the choice of a suitable analytical technology
and in maintenance. The following discussion focuses on
on-line analytical instruments in thermal power plants. A
few examples will illustrate the issue.
THE SAMPLING PROBLEM
When going through the records of the support depart-
ment it becomes obvious that steady and sufficient sam-
ple flow is one of the most frequent problems in steam and
condensate monitoring. As long as sample flow is not
measured and recorded, it is very difficult for a remote
support technician to detect the sampling problem.
Sample Flow Monitoring
We have, therefore, started to include sample flow moni-
toring as part of each and every on-line instrument. It
should not happen that an operator feels perfectly safe
with condensate conductivity while in reality the sensor is
sitting in a stagnant sample. Figure 1 shows a flow cell for
two conductivity sensors with cation column, needle valve
Figure 1: Flow cell for two conductivity sensors (specific
conductivity and cation conductivity) with
© 2005 by PowerPlantChemistry GmbH. All rights reserved. cation column, needle valve and flow meter.
PowerPlant Chemistry 2005, 7(12) 17
Process Monitoring: What Really Matters
Cost Effective Selection Same Parameter – Different Instruments
It is well known that pH in high purity water requires a lot Operators are often seduced by technical features.
of attention. Clever operators calculate pH from differential Automatic calibration and low detection limits are amongst
conductivity and save on maintenance. However, the the features many instrument manufacturers are proud of.
chemical treatment of the feedwater must be known. However, the question is: "What do you really need?" And
Purchasing departments without the necessary back- even more important: "What can you reasonably main-
ground will ignore this possibility and close the way to sav- tain?"
ings for many operators.
A simple sodium monitor has no moving parts and requires
manual calibration. Sample flow and reagent levels are
Sample Specific Selection controlled. The instrument is easy to understand and
everyone can service it (Figure 2a). A system for sodium
Monitoring disinfectants in cooling water discharge is now measurement in low pH samples is a bit more complex
required for most cooling towers. In many cases, this can and requires some maintenance (Figure 2b). If you really
be done by an amperometric device at low cost and with –1
have to see very low sodium levels, e.g., in the ng · kg
high reliability. Chemicals such as corrosion inhibitors or (ppt) range, in your condenser leakage detection, you
the use of chloramination call for a colorimetric device at absolutely need automatic calibration because low level
higher cost and more maintenance. Again, if purchasing standard solutions cannot be prepared in the laboratory.
ignores these facts, the cheaper instrument is chosen and However, there are pumps and valves that need mainte-
will have to be replaced later at high cost. nance (Figure 2c).
Figure 2a: Figure 2b: Figure 2c:
Standard sodium analyzer. Sodium analyzer with active reagent Sophisticated sodium analyzer featuring
addition for sodium measurement in low automatic calibration with standard
pH samples. dilution. This instrument is capable of
–1
measuring sodium in the ng · kg (ppt)
range.
18 PowerPlant Chemistry 2005, 7(12)
Process Monitoring: What Really Matters
The choice of the instrument depends on the plant and should always have a calibration history. It has much more
how it is operated. It is, therefore, very important to tell the value for quality assurance than any test with depleted
vendor what one plans to do with an analyzer. It is not standards or unsuitable methods.
enough to compare data sheets and select the fanciest
specifications.
WHAT REALLY MATTERS
MAINTENANCE It is not the data sheet, nor the fancy features! Reliable
operation of process monitors starts with right or wrong
Whenever an R&D engineer is asked for precise instruc- choices. Operators should have a word in making these
tions on maintenance he always tells us: "It depends…." choices because they have to live with what they get. What
There is no general rule for analyzers because sample is important:
quality varies from one plant to the other and even from
one sampling point to the other. Maintenance schedules – to control sample parameters, especially flow,
have to be established accordingly. In our records, we – to select the right instrument for a given task, and
have seen rather too much than not enough maintenance.
Most instruments give pretty stable results when left – to define a suitable quality control program.
undisturbed.
There is a lot of modern technology that will help to con-
Calibration trol essential instrument and sample parameters from a
remote location such as a central laboratory. The key,
Do not try to calibrate when standards are difficult to pre- however, is not the transmission technology but the data
pare or when there is a lack of trained personnel. A reliable that is transmitted. There are already a few happy station
trend has more value than an insecure accuracy. It is good
chemists who can tell from their home if a cation column
practice to not calibrate too often but check values from
in the plant is exhausted or if a silica analyzer requires
time to time with a standard or with a portable instrument.
servicing.
Sometimes operators want to calibrate electronics and
signal outputs. Modern instruments, however, have no
potentiometers. Calibration data is stored in the EEPROM
Paper presented at the Eskom International Conference on
and the system remains stable for years.
Power Plant Chemistry, Mabalingwe, South Africa,
November 8–11, 2005.
Accuracy
In many process applications the term "accuracy" has lim-
ited meaning because there is no valid reference value.
–1
How would you test the 5 µg · kg (ppb) reading of a dis-
solved oxygen meter? Sometimes samples are sent THE AUTHOR
around the globe to test for traces of sodium. With disas- Ruedi Germann worked for 20 years as an independent
trous results, obviously. business consultant before joining the management of a
Swiss-based international instrumentation company. He
From experience we know that calibration data is a good started SWAN Analytical Instruments in a management
indicator. If this data is within certain limits, the probability buy-out in 1991 and has served as managing director ever
of an accurate reading is high (Figure 3). Therefore, you since. The company has realized several information tech-
nology projects that integrate analytical instruments with
modern software tools for quality assurance applications
in thermal power plants.
CONTACT
Ruedi Germann
Swan Analytische Instrumente AG
8616 Riedikon
Switzerland
Figure 3: Accuracy and precision. E-mail: [email protected]
PowerPlant Chemistry 2005, 7(12) 19
