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SOR SENSOR Heavy Products Sampling Systems (HPSS Series)

Name: SOR SENSOR Heavy Products Sampling Systems (HPSS Series)
Brand: SOR

The SENSOR Heavy Products Sampling System (HPSS) by SOR Controls Group is engineered for the safe, reliable, and representative collection of hot, high-viscosity hydrocarbon liquids without operator exposure or line plugging. Designed specifically for challenging refinery and petrochemical streams—including vacuum tower bottoms, asphalt, hot tar, atmospheric resid, heavy gas oil, synthetic resins, polymers, and abrasive slurries—the HPSS incorporates three patented core innovations: a Removable Cartridge Valve, a Condensate-Free Steam Flush Assembly, and a Tool-Less Twist-Lock Purge Adapter. The cartridge valve design allows critical internal seals and trim to be serviced or replaced without removing the flanged spool from the process line, eliminating costly unit shutdowns. A steam-jacketed dispense tube and a 3-way steam-trap manifold ensure that only dry, condensate-free steam is delivered to purge lines after each grab cycle, guaranteeing 100% fluidized flow, zero vapor lock, and zero cross-contamination.

Safe collection of hot, viscous liquids up to 850 °F (454 °C) and 2,000 psig without operator exposure

Removable Cartridge Valve: valve internals can be swapped in minutes without unbolting the spool piece

Condensate-free steam flush assembly with 3-way needle valve and thermodynamic steam trap

Tool-less Twist-Lock Purge Adapter contains residual steam flush and routes it cleanly to the drain hose

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Product SeriesSOR SENSOR HPSS Series (Heavy Products Sample System)

Design StandardsASME B31.3 Process Piping, API 555, OSHA 1910 Compliance

Maximum Operating Pressure2,000 psig (137.9 bar) max

Maximum Operating Temperature850 °F (454 °C) max with Graphoil packing

Sample Valve Type316SSL Cartridge Type with High Viscosity (HV) enlarged port

Process Spool Piece316L Stainless Steel standard (1" to 4" ANSI 150# to 600# Flanged)

Dispense Tube316SS 3/8" or 1/2" OD, steam-jacketed / steam-traced

Valve Seals & PackingDie-formed Graphoil standard for high-temperature service

Steam Flush SystemCondensate-free 3-way needle valve with integral steam trap (25-150 psig steam)

Purge Adapter316SS Twist-Lock quick coupling with metal flexible drain hose

Enclosure Material304 Stainless Steel (insulated or non-insulated options)

Mounting Configuration2" x 60" Galvanized or 304SS Pipe Stand

Applicable MediaResid, Asphalt, Hot Tar, Heavy Gas Oil, Resins, Polymers, Slurries, Emulsions

Engineering Specifications & Selection Matrix

SOR SENSOR HPSS Heavy Products Sampling System Technical Data

Comprehensive engineering parameters, material configurations, and design options for SENSOR HPSS heavy product sampling stations.

Max Pressure2,000 psig (137.9 bar)

Max Temperature850 °F (454 °C)

Process Conn1" to 4" ANSI Flanged

Valve Type316SSL Cartridge Valve

Standard HPSS Models & Process Configurations

HPSS-100-F150HPSS Sampling System, 1" ANSI 150# Flanged Spool, 316SS Cartridge Valve, 304SS Enclosure

HPSS-150-F300HPSS Sampling System, 1.5" ANSI 300# Flanged Spool, 316SS Cartridge Valve, 304SS Enclosure

HPSS-200-F300HPSS Sampling System, 2" ANSI 300# Flanged Spool, 316SS Cartridge Valve, 304SS Enclosure

HPSS-200-F600HPSS Sampling System, 2" ANSI 600# Flanged Spool, 316SS Cartridge Valve, 304SS Enclosure

HPSS-300-F300HPSS Sampling System, 3" ANSI 300# Flanged Spool, 316SS Cartridge Valve, 304SS Enclosure

Performance Enhancements & Safety Accessories

OPT-PICPressure Isolating Chamber (Sample Cooler / Fixed Volume Chamber)

OPT-EDUSteam / Air / Nitrogen Motive Eductor for Enclosure Smoke Exhaust

OPT-SBVSecondary Process Block Valve for Double Block & Bleed Compliance

OPT-INSThermally Insulated 304SS Enclosure with Internal Steam / Electric Heater

OPT-MNT2" x 60" Galvanized Steel Floor Mount Pipe Stand

Model Coding Architecture

HPSS-200-F300-SS-PIC

HPSSBase ModelHeavy Products Sample System

200Spool Size2" Nominal Pipe Size

F300Flange RatingANSI Class 300 Flanged

SSMetallurgy316/316L Stainless Steel

PICOptionPressure Isolating Chamber Included

Technical specifications

Max Operating Pressure2,000 psig (137.9 bar)

Max Operating Temperature850 °F (454 °C)

Sample Valve Material316SSL Cartridge Type with High Viscosity Port

Packing MaterialDie-formed Graphoil rings

Dispense Tube Size3/8" to 1/2" OD, steam heated

Steam Supply Requirement25 to 150 psig saturated steam

Enclosure Construction14-gauge 304 Stainless Steel with Sloped Top

Enclosure Drain1/2" or 3/4" FNPT connected to flexible purge hose

Applicable Fluid ViscosityUp to 50,000+ cSt (resids, tars, asphalts, heavy oils)

Warranty1-Year SOR Controls Group Limited Warranty

Operational & Maintenance Guidelines

Always verify steam supply pressure and check that the steam trap valve is open prior to initiation.

Ensure sample container is securely placed beneath the dispense tube before opening the cartridge valve.

After taking grab sample, lock the twist-lock purge adapter onto the stinger and open the steam purge valve for 15-30 seconds.

Inspect Graphoil stem packing annually; adjust gland bolts or replace cartridge core during scheduled unit turnarounds.

Engineered Solutions for Hot, Viscous Process Sampling

Sampling high-viscosity refinery bottoms, molten asphalt, and heavy gas oils presents severe operational challenges: media solidifies rapidly upon cooling, plugging conventional sample taps, while extreme process temperatures (up to 850 °F) present critical burn and auto-ignition hazards to operating personnel.

The SENSOR HPSS system solves these problems by enclosing the entire dispensing point inside a heavy-duty stainless steel cabinet equipped with steam tracing, a steam-jacketed dispense stinger, and an automated condensate-free purge cycle. Operators can safely collect representative grab samples into metal cans or glass containers, then lock the purge adapter in place to flush the entire passage with dry steam, leaving the station completely clean and ready for the next cycle.

Enclosed containment isolates personnel from hot splashes, toxic vapors, and radiant heat

Continuous steam tracing keeps all process-wetted components above the fluid pour point

Eliminates hazardous open-bucket sampling and uncontrolled valve draining in refinery units

Pre-engineered modular design simplifies field installation and reduces maintenance overhead

Key Technological Innovations

Removable Cartridge ValveAllows internal valve stem, seats, and seals to be unbolted and serviced in under 10 minutes without cutting or unbolting the main process spool.

Condensate-Free Steam FlushDedicated 3-way valve and thermodynamic trap purge cold condensed water to drain before injecting pure, dry steam into the sample pathway.

Twist-Lock Purge AdapterConnects securely by hand to the dispense tube, directing purge steam and heavy residuals through a flexible stainless steel line directly to the closed drain.

Pneumatic / Steam EductorUtilizes plant air, nitrogen, or low-pressure steam to draw a slight vacuum inside the cabinet, exhausting smoke and vapors to an off-gas header.

System Configuration & Engineering Options

Pressure Isolating ChamberCools sample media below auto-ignition or smoke point before atmospheric container filling; provides repeatable fixed volume.

Secondary Block ValveFulfills facility double-block-and-bleed (DBB) process safety isolation mandates.

Insulated Enclosure HeatingAvailable with fiberglass insulation and internal steam coils or explosion-proof electric space heaters.

Exotic MetallurgyConstructed in Monel 400, Hastelloy C-276, or Inconel 625 for severe sour (H2S) or acid gas services.