THE BEGINNERS GUIDE TO

INDUSTRIAL
REPRESENTATIVE
SAMPLING

Why representative sampling is

important to operational success
 Running an efficient operation requires controlled, real-time
data obtained through representative sampling.
What is representative sampling?
Representative sampling is the act of capturing a limited volume of material from a process stream that accurately reflects the
characteristics of the entire lot, batch or process stream. Most material within a production environment or when being stored
and transported can be sampled and then analyzed for product quality and process monitoring.
Basic grab sampling such as a bucket and spigot collection or a bin scooping method merely reflect insights into the process
stream at the point in time when the sample was collected. Depending on the characteristics of the materials being sampled and
the process conditions, a grab sample may not be suitable due to segregation or separation. It also can be very dangerous. There
are also many human errors that can come into play when using a grab sample approach, creating uncertainty in the sample
analysis results.
On the other hand, composite sampling consists of a collection of numerous individual samples taken at regular intervals over
a period of time using the appropriate sampling technique for the application. The material being sampled is collected into
a sample container for analysis off line in a laboratory, or the sample is conditioned and sent directly to an on-line analyzer.
Additionally, the number and specific locations of your samplers has an impact on whether they truly will be representative of
your complete process.

REPRESENTATIVE SAMPLING BENEFITS

The controlled methods of representative industrial sampling:
Provide reliable and accurate analysis results
Save money by reducing waste and downtime
Protect operators and the environment
Ensure product quality and regulatory compliance
Lets take a closer look at how representative sampling helps chemists, maintenance planners, engineers, plant managers, QA
managers and operators collect reliable samples. Representative sampling combines safety, simplicity and accuracy to deliver
benefits unmatched by other sampling methods.

RELIABLE AND ACCURATE ANALYTICAL RESULTS

Garbage in, garbage out. This expression originating from the computer
science industry refers to an electronic device (a computer) that will
unquestioningly process unintended input (garbage in) to produce
nonsensical or undesired results (garbage out). This sentiment
certainly applies to sampling and analysis, conducted either in
situ or off line in a lab.
To avoid garbage inputs and increase confidence in your
product quality or process, obtaining representative
samples for accurate analysis is dependent upon the
application and the quality of the sampling methods
themselves. Or in other words, your sampling

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 method should be designed for the specific process stream, process conditions, materials characteristics, safety hazards,
certification standards and regulatory requirements.

TYPICAL SAMPLE APPLICATION CRITERIA

PROCESS MATERIALS
PROCESS STREAM SAMPLE TYPE
CONDITIONS CHARACTERISTICS
Conveying Area Classification Gas Abrasive
Distillation Towers Composition Liquid Boiling Point
Mixers Corrosiveness Powder Density
Pipes Flammability Slurry Explosive
Reactors Flow Rate Solid Freezing Point
Storage Vessels Pressure Steam Hardness
Radioactivity Water Magnetic
Temperature Moisture Content
Toxicity Particle Size
Particle Shape
Material Compatibility
Thermal Conductivity
Stratification
Vapor Pressure
Viscosity

Should these application criteria be overlooked, the samples taken will not sufficiently represent the complete lot, batch or
process stream. Most importantly, many samples may need to be conditioned by bringing the temperature, pressure and flow rate
to a suitable state for reliable analysis. Should this conditioning step be ignored or not conducted properly, the sample analysis
results could lead to misguided operational decisions that directly impact customer loyalty, profitability or safety.

SAVE MONEY BY REDUCING WASTE AND DOWNTIME

Process monitoring
Representative sampling and analysis is essential for efficiently monitoring plant processes and maximizing output. Many
operating environments run very harsh materials through their equipment. Plant assets
are a significant investment and vital to the success of maximizing output
and profitability. Therefore, monitoring is an important part of process
control for many industries, especially power generation, oil & gas,
petrochemical, chemical and others.
To regularly monitor the chemical properties of the process
stream and their impact on pipelines, storage tanks, turbines
or other equipment, representative sampling must be
collected, conditioned as needed and regularly analyzed to
avoid downtime. Neglecting monitoring puts your plant
assests and equipment at risk of catastrophic failures,
environmental spills or, even worse, fatal accidents.

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 Yield improvement
In the food and beverage industry, as an example, a plant must maintain proper moisture content to stay profitable. To avoid
potential product waste, the moisture content of ingredients or finished food products must be monitored by representative
sampling and analysis in order to:
Detect moisture irregularities
Identify over-drying or under-drying
Screen for product breakage
One specific way a plant can improve its yield is by keeping ingredient moisture content in the proper band. If it is too low, a plant
may be giving away product, and if it is too high, the product will deteriorate more quickly. Improper moisture content also is key
in product shrinkage or expansion, which directly affects the volume a product takes up in packaging. Plus, by sampling after a
dryer, a plant can not only identify if a product is being over-dried or under-dried, but also monitor and control the drier power
consumption.
In addition, sampling can help monitor product breakage to identify potential disruptions or issues within the process. Poor
performance of the sizing equipment can result in a direct increase in product needing to be discarded in landfills or sold at lower
price points for non-target users.

Process optimization
In the power generation industry, for example, automated sample conditioning and analysis systems easily and safely condition
and analyze with limited human interface. In a chemical or food processing plant, for example, an automatic sampler can ensure
sample integrity and provide several other advantages:
Production continues during sampling with no downtime
The sampler controller can be incorporated into existing equipment to allow sampling to begin
without operator engagement
Operators are not exposed to potentially harmful equipment pressure and temperatures
Consumer protection is enhanced because operators cannot inadvertently contaminate the process
Plants can cycle up much faster, saving time and money

PROTECT OPERATORS AND THE ENVIRONMENT

In many manufacturing plants or facilities, process streams are maintained at certain temperatures, pressure and flow rates.
The vessel from which the sample is retrieved pipes, tanks, mixers, conveying
belts, chutes, towers, reactors or other equipment must be taken into
consideration in developing the best sampling method. Automatic
or manual samplers or fully integrated sample conditioning and
analysis systems should be installed in the right location(s),
capturing the right sample volumes at the right frequency
using a sampling technique compatible with the application
criteria.
Each operation is different, yet your product quality
and processes must be consistent, based on trusted
data. Thats why your sampling methods must be
compatible with the characteristics of the process

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 material to ensure safety without sacrificing representation. For example, sampling a gas that is extremely flammable held
under high pressure in a pipeline would require a very different method than a small particle-sized solid material free flowing
from a conveyor belt. Or a viscous slurry with moisture content would require a different sampling solution than a radioactive
wastewater application.
Many operational environments must handle hazardous products or wastes such as deadly H2S (hydrogen sulfide) sour gas or
water, explosive materials or toxic or abrasive materials. A grab sample approach in this type of environment would pose a health
and safety risk to operators and the environment.

Operator safety
Many manufacturers are closely aligned to regulations that ensure the safety of their employees. For example, The Occupational
Safety and Health Administration (OSHA) enforces U.S. federal government mandates regarding workplace safety, while the
International Labour Organization (ILO) works with over 180 member countries to ensure occupational safety and health for
workers. Employers are required to strictly follow employee safety regulations or risk sanctions and other penalties.
To that end, closed-looped, representative sampling is an ideal solution. The design of these samplers protects operators by:
Keeping liquids and gases fully contained to eliminate worker exposure to hazardous vapors
and potentially scalding fluids
Using a series of valves and vents that control very low-emission sampling instead of
unprotected buckets and spigots
Leveraging sampling system automation to reduce the need for human operational steps
and minimize risk in extreme plant conditions

OSHA Defined
The main goal of the Occupational Safety and Health Administration (OSHA) is to protect the rights and safety
of workers by preventing workplace injuries and deaths. OSHA holds employers accountable for safe workplaces
through a strict set of U.S. federal safety standards that cover things like hazardous materials disposal, required
personal safety equipment such as safety goggles, permitted noise levels and fall protection.

ILO Defined
The International Labour Organizaton (ILO) aims to ensure that it serves the needs of working women and men
by bringing together governments, employers and workers to set labour
standards, develop policies and devise programmes. The very
structure of the ILO, where workers and employers together
have an equal voice with governments in its deliberations,
shows social dialogue in action. It ensures that the
views of the social partners are closely reflected in
ILO labour standards, policies and programmes.

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 Environmental safety
Protecting the environment from harmful contaminants that can have an impact on our soil, air and waterways, as well as the
planets climate, now and well into the future, requires diligence and discipline. To be good citizens of the planet, nearly all
facilities or plant factories are required to adhere to environmental regulations, some more than others. The Environmental
Protection Agency (EPA) is empowered by the U.S. federal government to oversee protection of the natural environment and
human health. Broadly speaking, the EPA regulates the manufacturing, processing, distribution and use of chemicals and other
pollutants. Internationally, The United Nations Environment Programme (UNEP) sets environment protection policy through the
United Nations.
For compliance, closed-looped, representative sampling and corrosion monitoring solutions are ideal. The design of these protect
the environment by:
Minimizing the potential for spills of contaminants
Stopping prolonged release of toxic vapors into the air
Reducing sample testing sizes from a bucketful to the minimum volume necessary,
which eliminates leftover sample waste and concerns over its safe disposal
Sampling and measuring process waste streams for contaminants before release back into
the environment

EPA Defined
The Environmental Protection Agency (EPA) is a U.S. federal organization that conserves the natural environment
and improves human health by researching and regulating the manufacturing, processing, distribution and use of
chemicals and other pollutants. In addition, the EPA is charged with determining safe tolerance levels for chemicals
and other pollutants in food, animal feed and water.

UNEP Defined
The United Nations Environment Programme (UNEP) is the leading global environmental authority that sets
the global environmental agenda, promotes the coherent implementation of the environmental dimension
of sustainable development within the United Nations system and serves as an authoritative advocate for the
global environment.

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 Food safety
You are what you eat. That old adage refers to nutrition, yet takes on new meaning when it comes to food safety. Trace levels of
toxins and pesticides, contaminants and micro-organisms all pose real public health risks as well as potentially serious financial
and criminal damages to food and beverage brands.
The U.S. Food and Drug Administration (FDA) is responsible for controlling safety standards in food, drugs, cosmetics, animal food,
dietary supplements, medical devices, biological goods and blood products. To ensure compliance with government protocol
and the recent FDA Food Safety Modernization Act of 2010 (FSMA) legislation that expands FDA jurisdiction, frequent sampling
and food safety testing is required. Yet, food safety is a global food supply issue with the import and export trade of foods and
ingredients. Having complete confidence in food sampling and analysis results from raw ingredients to finished product is critical.
To reduce risk, automated, representative sampling solutions expedite the process and:
Ensure food safety testing is accurate and reliable to avoid product recalls
Identify and prevent microbial, allergen or chemical contamination by sampling throughout
the production process
Validate raw ingredients authenticity and quality
Help producers confidently report and trace product lots and batches to comply with
food safety regulations
Ensure sample integrity with easy-to-clean, sanitary designs and FDA-approved seals

FDA Defined
The Food and Drug Administration (FDA) is an agency of the federal government that is responsible for monitoring
trade and safety standards in food, drugs, cosmetics, animal food, dietary supplements, medical devices, biological
goods and blood products. In 2011, the FDA Food Safety Modernization Act of 2010 (FSMA) was signed into law and
granted the FDA new regulatory powers regarding food growth, harvest, and processing. The FDA also was given
mandatory recall authority.

World Health Organization INFOSAN Defined

The World Health Organization (WHO), International Food Safety Authorities Network (INFOSAN) contains national
authorities of 181 Member States are part of the network. Increasing globalization of food trade increases the
risk of contaminated food spreading quickly around the globe. Through INFOSAN,
WHO assists Member States in managing food safety risks, ensuring
rapid sharing of information during food safety emergencies to
stop the spread of contaminated food from one country to
another. INFOSAN also facilitates the sharing experiences
and tested solutions in and between countries to
optimize future interventions to protect the health
of consumers.

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 ENSURE PRODUCT QUALITY AND REGULATORY COMPLIANCE
In addition to complying with local, national and international regulations, a manufacturers commitment to quality and safety
leads to maintaining the highest industry standards and numerous national and international certifications. When you stop
to consider how standards and regulations work to foster customer loyalty, profitability and safety, why would they not apply
to your sampling methods as well? This is particularly true in markets like food and beverage, power generation, oil and gas,
petrochemical, chemicals, concrete and more, where safety and quality arent goals theyre expectations.
For example, a longstanding American Society of Mechanical Engineers (ASME) certification means materials strength, chemical
composition, and pressure testing and ratings comply with the strictest industry quality mandates. Sampling products that
receive the pressure vessel designation (ASME U stamp) guarantees their alignment with written ASME procedures, specifications
and test requirements. Sampling products also should adhere to National Association of Corrosion Engineers (NACE) standards
that are globally recognized as the authority in defining design criteria to ensure safe operation by mitigating corrosion.
Likewise, compliance with Hazardous Location (HAZLOC) requirements is of particular importance, where sampling needs to
accommodate dangerous, flammable and explosive environments. Thinking beyond on-location safety to on-the-road safety
means also maintaining the Department of Transportation (DOT) certification required to collect and transport pressure vessels
between sites for contents evaluation.
ASME certification and HAZLOC are not unusual within the process sampling industry, nor are their international counterparts
like the Canadian Registration Number (CRN), Conformit Europene (CE), Pressure Equipment Directive (PED), and the European
Directive for Equipment for Potentially Explosive Atmospheres (ATEX).
In the end, when a manufacturer partners with a sampling expert who also has ISO 9001 certification, this further assures that the
sampling solutions installed in their operations meets the quality management system recognized as world-class.

What are ISO standards?

International Standards make things work. They give world-class specifications for products, services and
systems, to ensure quality, safety and efficiency. They are instrumental in facilitating international trade.
ISO has published more than 19000 International Standards and related documents, covering almost every
industry, from technology, to food safety, to agriculture and healthcare. ISO International Standards impact
everyone, everywhere.

With proven sampling expertise since 1924, Sentry products and services provide business operations the critical insights to
optimize process control and product quality. We deliver true representative sampling and analysis techniques to customers
around the globe, empowering them to accurately monitor and measure processes for improved production efficiency, output
and safety. Standing behind our commitments, we are determined to tackle any application, anywhere.

Talk to a representative sampling expert today by calling

+1-262-567-7256 or by completing our online contact form.

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