Injection and Sampling Systems

for High Pressure (HPTM and MHTM) Access Systems

Protective Cover

Solid Plug

Access Fitting Nipple

To Feed Pump
Injection Nut or Sampling
Cylinder

Shutoff Valve

Quill Open NPT w/ Nozzle Head w/ Cap & Core

Figure 1

Injection and Sampling systems are fundamental to corrosion control and process control programs.
They are applicable to a large variety of processes in the petroleum, chemical, and water treatment
industries. Injection systems are used to inject a wide range of chemicals into processes. Such
chemicals include biocides, demulsifiers, corrosion inhibitors, oxygen scavengers, glycol and mono-
ethylene glycol, dewaxers, methanol, odorizers, and product additives.

Injection systems may be as simple as using an open-ended tube that allows for even distribution of
the injected chemical or as complex as using a head with a cap and core to obtain precise atomiza-
tion of the chemical.

Sampling systems are used to take samples of the process fluid or medium. Such samples are then
analyzed in the laboratory for inhibitor concentration levels, the presence of metal ions, oxygen lev-
els, scale forming compounds, and a wide range of process parameters.
Injection Systems Injection Point
The art of chemical injection is a complex The maximum fluid velocity is usually at the
technology. Irrespective of the type of injection center of the line. Therefore, the most effective
or injected fluid, several factors relative to the position for injection is generally at the center of
process system and the injection system must be the pipe in the direction of the product flow. If
considered. Principal factors are: the line is to be pigged, the injection point may
be flush with the pipe wall. This eliminates the
Pressure Differential need to remove the injection probe before pig-
This is the difference between the injection ging operations begin. On pipelines this means
pump pressure and the process line or vessel that injection is perpendicular to the product
pressure. Ideally the pressure differential should flow. Top of the line may be used if the injec-
be 100 PSI (6.8 Bar). However, varied injection tion is required to be oblique or horizontal to the
rates can be achieved by changing the pressure product flow.
differential.
A typical Two-Inch System Injection Assembly
Temperature is shown in Figure 1. A Sampling system uses
Temperature directly affects viscosity. Ideally the the same components. The various components
temperature of both the injected chemical and of the assembly are:
the line product should be about 70° F (21° C).
1. An Access Fitting body with a side Tee
Viscosity through which the fluid transfer takes place.
This is the measure of a fluid's resistance to flow. The Tee may be threaded or welded. Welded
The more viscous the fluid the smaller the spray Tees are either flanged or buttweld nipples.
angle. Threaded Tees are based on an NPT tapped
hole in the fitting body. The Tee size is rated
Spray Angle according to the injection rate and viscosity
Spray angle is affected by viscosity, spray dis- of the injected chemical.
tance, and pressure differential.
2. A Solid Plug Assembly inside the fitting
Spray Coverage body is used to carry an injection nut that has
This is the theoretical coverage area. the injection tube/nozzle assembly screwed
into its base.
Specific Gravity
The specific gravity of a liquid is the density 3. An Injection/Sampling Nut is a multiple
ratio of the liquid to water. The flow rate of a use device that replaces the nut on the end of
liquid is affected by its specific gravity. the solid plug. It is used to direct the injected
product to the injection tube or atomization
Injection Rate device. An Injection Nut sizing chart is
This is the amount of chemical to be injected shown in Table 1.
within a specified time and is defined as Gallons
Per Hour (GPH), Liters Per Day (LPD), etc. In- 4. The Injection/Sampling Tube or Nozzle.
jection Systems are available for injection rates
varying from 0.1 GPH (0.38 liters/hr) to 65.7 a. Quill is an open-ended tube cut at a 45°
GPH (250 liters/hr). angle with a slot. It utilizes the turbulence
created by its unique design to achieve
distribution of the injected chemical into
Injection - 2
 the product flow. Injection Tube Quills 7. Check Valves are optional items that may be
are clog proof and give extremely good fitted either within the Injection Tube or in
dispersion of the inhibitor if the product the inlet line to the Access Fitting Body Tee.
flow is 15 ft. per second or greater. As
with the Open Tube, injection rate must 8. The Injection or Feed Pump must be
be controlled at the injection pump or capable of generating sufficient injection
shut-off valve. line pressure to overcome the line operating
pressure and thus create the required pressure
b. Open is an open tube. The natural turbu- differential across the atomizing nozzle or
lence within the pipeline is used to insure injection tube.
even distribution. There is essentially no
pressure differential experienced at the Materials of Construction
orifice, so it is necessary to control the All components are manufactured from 316 SS
injection rate at the injection pump or the as standard with the exception of seals and
shut-off valve. packing. These materials comply with the
requirements of NACE Standard MR-0175
c. NPT is similar to the Open Tube but is Recommended Materials for sulfide stress
threaded at the dispersion end, thus allow- cracking environments.
ing attachment of female nozzle assem-
blies. Injection may be perpendicular to Injection Tube Sizing
the flow with the use of a straight nozzle (Lengths are rounded down to the nearest 1/8".)
or parallel to the flow with the use of a
right angle nozzle. Center of Line Non-Flange Fitting
Open/Quill: (FH + PD/2) - (2.04 + N) = L
d. Head with Caps, Cores, and Strainers Head: (FH + PD/2) - (2.04 + N) = L
are the various devices that, when attached *NPT: (FH + PD/2) - (3.353 + N) = L
to the dispersion end of the Injection Center of Line Flange Fitting
Tube, permit atomization of the fluid as it Open/Quill: (FH + PD/2 + MF) - (2.04 + N) = L
is injected into the product line or vessel. Head: (FH + PD/2 + MF) - (2.04 + N) = L
The assemblies can be provided in com- *NPT: (FH + PD/2 + MF) - (3.353 + N) = L
plete units that contain caps, cores, and
Flush Non-Flange Access Fitting
strainers. The head has female threads Open/Quill: (FH + PW) - (2.04 + N) = L
to match threads on the caps, cores, and Head: (FH + PW) - (2.04 + N) = L
strainers, so that these attachments can *NPT: (FH + PW) - (3.353 + N) = L
easily be replaced.
Flush Flange Access Fitting
5. Nipples are used with threaded Tee Access Open/Quill: (FH + PW + MF) - (2.04 + N) = L
Fitting bodies and are the means of connect- Head: (FH + PW + MF) - (2.04 + N) = L
ing the shut-off valve to the Access Fitting *NPT: (FH + PW + MF) - (3.353 + N) = L
body.
FH = Access Fitting Height
PW = Pipe Wall Thickness
6. Shut-Off Valves are required to cut off the N = Injection Nut Length
injection flow and maintain pressure integrity L = Injection Tube Length
through the Tee when the Solid Plug Assem- MF = Mating Flange Height
bly is being removed or replaced. They are PD = Pipe Outer Diameter
also used to control the injection flow rate. IL = Insertion Length into Pipe or Vessel
A Nipple and Shut-Off Valve sizing chart is * Length of tube is based on nozzle length of 1.313".
given in Table 3. Nozzle is sold separately.
Injection - 3
How to Order
A) Access Fitting Body height and Tee size may be determined from the Access Fitting literature.
B) The Injection Nut size may be determined from Table 1.
Model Length (Fitting type / Height) Probe End Thread Seal Material Alloy Code
IQN --- ---- X ---- ---- X ---- ---- X ---- ---- XXX
1 - 1.75" (HP / 5.25") 0 - N/A 0 - N/A 158 - 316 SS
2 - 2.75" (HP / 6.25") 1 - 1/8" - 27 NPT 1 - Viton® o-ring / A12 - C276
3 - 3.75" (HP / 7.25") 2 - 1/4" - 18 NPT Teflon® backing ring
4 - 4.75" 3 - 3/8" - 18 NPT 2 - Ethylene propylene /
5 - 5.50" (HP / 8.25") 4 - 1/2" - 14 NPT Teflon® backing ring
6 - 3.50" (MH / all heights) 5 - 3/4" - 14 NPT 3 - Kalrez o-ring /
6 - 3/8" - 24 UNF - 2B Teflon® backing ring
7 - 7/16" - 20 UNF - 2B 4 - Hydrin o-ring /
8 - 1/2" - 20 UNF - 2B Teflon® backing ring
9 - 9/16" - 18 UNF - 2B 5 - Nitrile o-ring /
A - 5/8" - 18 UNF - 2B Teflon® backing ring
6 - Teflon® o-ring /
Teflon® backing ring
Table 1
C) Determine Injection Tube Thread size required. Determine the Type. Calculate the Injection
Tube Length using the sizing formulas. Use this information to determine the Part # from Table 2.
Model Thread Size Type Alloy Length Designation
IQ --- ---- X ---- ---- XX ---- ---- XXX ---- ---- XXXX
1 - 1/8" NPT 01 - Quill 158 - 316 SS Length in inches,
2 - 1/4" NPT 02 - Open A12 - C276 stated in 2 decimal
3 - 1/2" NPT 03 - NPT for a Nozzle place format
4 - 3/4" NPT 04 - Head w/ Cap & Core (Ex: 6 1/8" = 0612)
Table 2
D) A Nipple & Shut-Off Valve to match the Tee of the Access Fitting Body may be selected from Table 3.
Valve Nipple, 4 in (100 mm)
Access Fitting 316 SS 316 SS Sch. 80
Tee Size
Part No. Part No.
1/4" HA700022158 HA700018158
1/2" HA700023158 HA700019158
3/4" HA700027158 HA700020158
1" HA700029158 HA700021158
Table 3
E) If applicable, select a suitable Nozzle Type or Cap & Core Assembly from Table 4.
Nozzle Type / Part Number Orifice Expected Flow Rate
1/4" FNPT Noz. 1/4" MNPT Noz. Cap & Core Assem. (9/16") Size in GPH @ 100 PSI

PR626213903 PR609713903 PR617613903 .006 .48

PR626213904 PR609713904 PR617613904 .012 .64
PR626213906 PR609713906 PR617613906 .016 .96
Table 4
Metal Samples Corrosion Monitoring Systems
A Division of Alabama Specialty Products, Inc.
152 Metal Samples Rd., Munford, AL 36268 Phone: (256) 358-4202 Fax: (256) 358-4515
E-mail: msc@alspi.com Internet: www.metalsamples.com
Houston Office: 6327 Teal Mist Lane, Fulshear, TX 77441 Phone: (832) 451-6825