Prepared by:

Shailesh Ghediya
Sampling is done in order to analyze the parameters
required for control of the process.

Sampling can be classified into two types:

Open sampling
Close sampling

In open sampling the sample comes in contact with
atmosphere.
For the streams whose temperature is less than auto ignition
temperature, which is free of H2S or any toxic gas which is
not high flammable open sampling is done.
In short, open sampling is advisable for the streams which
do not lead to fire, H2S inhalation and danger to life.


Open sampling set up will have process coil immersed in a
water bath (cooler).
Inlet of the Process coil setup will be from process line and
the outlet line will be either circulated or routed to slop tank
to get fresh stream of the sample and not the holdup material
which is undesirable.
Streams like VGO feed, VGO product and Diesel can be taken
in open sampling setup.
Similarly steam and steam generator blow down /condensate
sample can be taken by open sampling set up.

Closed sampling is done in sample bombs at approved
sample stations meant for closed sampling.
Recycle gas, Sour water, Naphtha, Propylene have to be taken
as close sample.
Recycle gas can be taken as bladder sample only as a special
requirement and required safety precautions and procedures
to be followed while pursuing the activity
Hazards Precautions
Hot HC material coming during
sampling.

Accidental touching of sample
booth coil (In case of open
boot)

Splash of hot liquids



Hydrogen can lead to
Fire/explosion
Always open water in sample
cooler before opening any
process valves.

Heat resistance gloves to be
use along with mandatory PPEs

Operate sampling station
valves slowly.
Wear splashguard helmet
during.

Keep sure that sample bombs
are tested at regular intervals

Hazards Precautions
Slip hazards due to slippery.

Sample bomb rupture disc
failure






Person getting hot and cold
burns due to nearby hot
surfaces



Use Mandatory PPES

Do not let bomb in hot
atmosphere to avoid high
pressure.
Handle sample bomb with care
to avoid any physical damage
to inlet/outlet valve
connection.
Hydro test is done periodically.

Ensure lines are properly
insulated



Ensure Fire Water Hose is ready for use.
Ensure valves A, B, C, D & E are closed.
Open valve E keeping D closed, which fills sample station cooler with water
And let water overflow through the overflow line.
Slowly open valve B.
Open the valve A and allow the hydro carbon to flow.
Keep circulation on for 4-5 minutes.
Close the valve B Slowly.
Slowly open valve C, Keeping the glass bottle for sampling in such a way that
it is away from body of the person taking the sample.
Adjust the flow rate of sampling stream such that it gets cooled so that
bottle can be held comfortably. With gloves on.
Flush the sample bottle and take sample.
Close the valve A ,Close the valve C &Close cooling water supply valve E.
Open valve D to drain the sample cooler water.
Shift the sample bottle to sample station holding it comfortably and securely.

Inform panel officer for sampling with specific location of sample
point with sample name.
Ensure that system is de pressurized & all valves are closed. Confirm
in the PG. It should be 0.1-0.2kg/cm2g
Insert the sample bomb in the bottom quick release coupling-1(QC-
2) connect the SS hose to the bomb top quick release coupling-
2(QC-2)
Open bomb valve V5,V6 & than V2, V3
Open main supply valve V2 than return valve V7.
Watch the PG for pressure in the manifold. It should match with
process pressure.
Let the sample flow through the bomb for 5-10 minute to flush the
bomb.
Close the bomb outlet valve V6.

After 1-2 minute close the bomb inlet valve V5 than close valve V2 &
V3
Close supply valve V1 & than return valve V7.
Open valve V4 & V8 to depressurize manifold, Confirm de-
pressurization with pressure gauge .It should be 0.1-0.2 kg /cm2
Close vent valve and release SS hose at the top of bomb than
disconnect bomb and Connect the SS hose at bottom QC-2

An area field executive from DTA aromatics unit received burn
injury while collecting sample
The temporary hose connection which was fitted between process
line and sampler got detached from joint
This result into splashing hot condensate over his chest area causing
8-10% burn injury on chest and right lower part of cheek.
Injured person was given medical treatment at our DA OH &FWC and
total lost work days were 13 days
Over pressurization.
Synchronization of valve A &C.
The wire braided rubber hose which is design for LP steam
service (working pressure 10 kg/cm2 and temp 150 deg C.)
found in use for MP steam.
The hose was connected with single C clamp instead two.
Temporary hose was supported using wire.
There is no formal system exist for doing necessary checks
on integrity of temporary hose connection using check list.
There was no formal record of HSE review /Risk assessment
available with operation for affecting the temporary change
There was no identification tag affixed on the hose.

Practice consistent with procedure
Absent of shortcuts
Risk sensitivity