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Sampling systems

Probenahmesysteme, Probenahme von Flüssigkeiten, Gasen, Schmelzen und Feststoffen
SMART-FVS Sampling system

New: Sampling system for extracting a fixed volume from process lines

With the SMART-FVS a fixed volume is isolated by turning the operation handle by 180°. The medium flows through the system in home position and is capsuled by manually moving the operation handle to separate a fixed and representative volume of any liquid media into the bottle for further handling.

Technical specifications can be found here.


An overview of our sampling systems

Samples are necessary to optimise process engineering processes, control and check chemical reactions or to be able to check the quality of input materials, intermediate and end products. Sampling plays an important role in this. Sampling systems must make it possible to intervene in closed processes without danger.

The design of a sampling device is aligned to

•    The special material properties of the product to be extracted
•    The physical condition of the material to be extracted at the place of extraction
•    Safety technical requirements of the operator
•    General technical requirements including legal frameworks
•    Design constraints.

It is absolutely imperative to extract samples securely, representatively and free of dead space.

The wide variety of balanced requirements requires the individual design of optimum sampling systems. In order to attain this goal close cooperation with the customer, represented by operation, analytical technology and safety at work, is necessary. We will be pleased to make our many years of experience and high level of flexibility in the design and manufacturing processes available to you

We provide individual solutions for the:

•    Sampling of liquids
•    Sampling of liquids with sample cooling
•    Sampling systems with sample cylinder
•    Sampling of gases
•    Sampling of molten masses
•    Sampling of solids

Sampling of liquids

In addition to standard solutions like sampling valves with hand wheel and bellows or valves with dead man's handle without safety cabinet, we provide you with liquid samples with protective shield and safety cabinet. This design enables safe filling of the bottle without the liquid spraying over the bottleneck. At the same time the gases and vapours suppressed by the product are dissipated via an annular gap in the head of the bottle. We can offer the safety cabinets for sampling systems with lighting or viewing window and various seals as an option.

If a fixed extraction volume is required we provide a special system for this purpose. With this sampling system a sample volume of 230 ml is transferred outwards when the hand lever is turned through 180°. In this way the constant volume is filled in the sample bottle.
In the basic position the product flows through from the sampling tap. The complete sampling process occurs when the hand lever is activated. In doing so, the product inlet and outlet are closed first of all. As a result the sample volume is separated in the tap. When the hand lever reached its end position, the sample outlet and the inertisation are opened parallely. The sample is filled in the bottle and it is available for further handling.
The sample bottle is in a safety cabinet depending on the version of the sampling system. This sampling tap can also be equipped with a pneumatic actuator.
In addition we offer a sampling system for liquids and also vertical pipes in an enameled version for particularly corrosive media or in needle/septum technology. The sampling of liquids with sample cooling also forms part of our scope. This type of sampler is used for the sampling of liquids at higher operating temperatures and to extract platformate at 180 °C, methyl ethyl ketone toluene mixtures or also furfural at temperatures up to 150 °C and operating pressures up to 12 bar among other things.

A ribbed cooler is flanged below the extraction fitting in solid construction. This cools the sample quickly and also enables the enclosure of a defined sample volume (up to 200 ml possible).

A sampling system with a bypass line is designed for the sampling of gas emitting liquids i.e. liquids with a high vapour pressure. Fresh product constantly flows through it. The sampling process enables the path from the constantly purged bypass line to be cleared for the sample if the one hand control device is activated. The control valve further back in the direction of flow is closed during this process. The complete product flow in the bypass line flows through the sample container. At the same time the operating pressure in the system is controlled via the manometer display.

The one lever operation with automatic spring reset is provided with a limit circuit against the fire safe ball valves of the vent pipe (slop system).
When the one hand device is activated a bolt is forced into the operating mechanism of these release taps so that it is not possible to open the release valves during the filling of the sample container.

The sample container can easily and securely be connected to the sampling system and an appropriate laboratory docking station via screw locks. The sample cylinder is secured against overfilling with an immersion tube.

Sampling of gases

The sampling of gases occurs via gas extraction stations with nitrogen purging which are controlled by a multi-port ball valve. The sample cylinder (150 ml) is then filled with nitrogen in order to obtain a representative sample. Subsequently the cylinder can be filled with the gas sample. In doing so it must be ensured that there is adequate through flow as non-representative initial flow must be discharged. The through flow can be set with the help of a regulating valve and a flow meter in the range from 0.4 to 6.0 l/min.

After the gas cylinder has been filled with a representative sample in this way, switching to the bypass cylinder occurs via two multi-port ball valves and the sample is thus separated at the same time. In order to purge the pipe system it is possible to discharge the residual gas phase via the nitrogen pathway (purging system).

After this the sample cylinder must be separated from the station without danger and taken from the cabinet.

The sampling system is provided with a safety valve. Sufficient differential pressure for through flow must be guaranteed. The system to the outflow can be shut off via a ball valve.

Sampling of molten matter

For molten matter samplers for extracting bitumen, liquid sulphur, molten phenol matter etc., the sampling system is connected sideways to the pressure vessel via a flange connection.

The safety technology of the system combines the channeling process with the safety cabinet solution - both are safety technical aspects which are also recognised as state of the art by BG Chemie and recommended. So a fixed sample volume is enclosed and overfilling of the sample collection vessel is prevented. The safety cabinet creates the spatial separation between the filling process and the operating elements necessary for sampling. These are placed on the outside of the cabinet.

The sampling system is activated via two spring resetting pneumatic actuators. These are controlled with the help of a multi-port valve which guides both actuators to the closed position (ZU) when not activated. The control valve can be moved up from this safety position in order to open the sample inlet and the sample outlet can be activated by moving it in the opposite direction. If there is a control change the safety setting closed (ZU) is the default setting.
The control air for the pneumatic actuators is released by closing the cabinet door. The system activation is installed in such a way that manipulation without the aid of a tool is not possible.

The valve opens the valve cone in the process. The additional sealing force from the process pressure is used. A ball valve is provided in the sample outlet so that a defined sample volume is separated between this and the first barrier (inlet valve).

The sample chamber is filled with control air or N2 via a purging connection which is led to the first barrier and thus supports the sample discharge. This is particularly advantageous when extracting highly viscous products. The purging is introduced by a corresponding relay of the pneumatics in parallel with the sample filling.

Double jacketed steam heated molten mass samplers are another possible version. Here the valve body and the sample pre-chamber are heated up to the ball valve. Here too filling takes place in a safety cabinet.

Steam heated molten mass samplers for pipes are mainly designed as bottom valves. The product flows through the valve. The flow is not interrupted by the sample being taken.

The pipe which conveys the product is guided through the safety cabinet so that the outlet path is reduced to a minimum.

•    Designed for up to 450 °C
•    Double jacket (designed for 40 bar)
•    Flange connections according to DIN EN
•    Activation manual or via hand controlled pneumatic actuators
•    Pneumatic interlock circuits for a high level of safety at work

Sampling of solids

The system of taking samples from downpipes through a cross section collector is the most precise one. The device captures the complete product flow and extracts a representative cross section of it as may be required for a convincing analysis of grain size for example. The extraction of solids occurs via a tilting funnel with an outlet slope which collects the sample over the complete pipe cross section with a 90° tilting motion. The sample material falls freely into the sample bottle or connected devices for further sample processing. The tilting funnel is parked outside the product flow when it is not being used. 

The sampling system is activated pneumatically and it can be operated with the help of a control valve in manual operation or it can be fully automated via a control system.

With piston valves the piston of the valve closes flush to the inner wall of the container or pipe in the off position and cannot be moved forwards beyond this position. The significant advantage of this is that components do not project into the process at any point so that the free product flow is not obstructed. This also means that stirrers can continue to be used during the sampling.

•    Residual product can be blown out of the discharge path into the bottle via a purging connection
•    Block flange connections and fitting pieces can be provided with connection flange
•    Activation with control valves in manual operation or automatically via a control system
•    Bottle connections according to process requirements and customer requirements

180° solid samplers for downpipes are used in the pharmaceutical and food industries for example and they make a representative proportional sample possible over a longer period of time. The sample outlet and the connected system units are fully shut off from the process when they are not in use in between periods of extraction. This aspect is relevant for safety and also makes straightforward maintenance and cleaning in place possible.

The appliance is normally used for the extraction of dry, free flowing solids and it extracts representative samples of fixed defined volumes from downpipes. It can be controlled by hand or operated automatically. The solid sampler is fitted to a block flange welded into the downpipe or fitted on a fitting piece. The extraction volume is 20 ml.

For rotating samplers a sample is taken with a maximum rotation of 120°. A polished inner pipe rotates within a fixed guide pipe. For sampling, the opening apertures of the two pipes overlap and the sample material trickles out freely. The sample remains in motion in this way through the complete discharge path and does not come under mechanical load. The large free cross sections are also beneficial.

The sample quantity intercepted can be varied depending on the speed of the rotating movement. The solid sampler can be automated for proportional sampling over a longer time period. Connection and materials are implemented according to customer instructions

In the field of solid samplers we also offer the following in various versions:
•    Piston samplers
•    Screw samplers
•    Manually operated solid samplers

Any questions?

You have questions about products or solutions in Sampling systems? No problem, we will help you.

Joachim ScholzJoachim ScholzVertrieb+49 (0)40 398202-55
Ulf FeddersenUlf FeddersenVertrieb+49 (0)40 398202-52

Our range is far from being exhausted. Tell us what you need. We have the right solutions!

The efficient way to take samples

Samples are needed for optimizing production processes, controlling and monitoring chemical reactions, and checking the quality of input materials, intermediate and end products. Sampling systems have to permit safe removal from closed processes and ensure that representative samples are taken without headspace.

We supply sampling solutions for solids, liquids, gases, melts and suspensions for temperatures of up to 550°C and pressures of up to 325 bar. Our sampling systems are used in the chemical and petrochemical industries, the pharmaceutical sector, and shipbuilding.

The materials we use to build our sampling systems include not only stainless steel, but also hastelloy, zirconium, tantalum, ceramics, titanium, enamelled steel etc.

Sampling system in security box

Probenahmesystem mit Schutzschrank

Fixed volume sampling system

Probenahmesystem mit fest definiertem Probevolumen

Bypass sampling system

Probenahmesystem für Bypassleitung

Sampling of gases with sampling cylinder

Probenahmesystem für Gase mit Probenzylinder

Sampling system for molten matter

Probenahmesystem für Schmelzen

Sampling System for molten matter

Probenahmesystem für Schmelzen

Sampling system for solids

Probenahmesystem für Feststoffe

180° Solids sampler

180° Feststoff-Probenahmesystem