O2 / Oxygen Analyser Maintenance
Oxygen Analyser Maintenance
The technology is very mature, reliable and stable. This however can lead to complacency and the measurements not being given the attention that they require until it’s too late. It is not uncommon for a new plant to be supplied, commissioned and handed over to the client who may have no interaction with the O2 measurements for several years.
For the EFW sector in particular, it is especially important to stay on top of oxygen analyser maintenance due to accelerated rates of attrition from aggressive and acidic gas streams.
O2 measurements are recognised in the design phase and typically installed in parallel and often triplicate to provide averaged and / or redundant measurements. This is sensible and allows for maintenance without loss of measurement and where in triplicate, if one device is erroneous, it is easier to identify and disable that measurement.
These devices are typically mounted in the boiler / economiser and so subject to aggressive gas with high dust loading. Over time this can clog the probe filters and a gradual deterioration occurs; a slow loss of performance that can dull response times and possibly reduce the combustion optimisation parameters that were set using new and quick-responding, heathy probes.
This however isn’t the biggest risk, and a replacement filter and calibration can return the device back to a healthy state.
What happens if the O2 analyser maintenance interval is left too long?
A significant issue we see is with corrosion – pitting of a probe tube, which over-time will become porous. In extreme situations, we have seen probes snap in two on removal! If an instrument is unusable and no spare is held, this can cause anxiety for the operator.
If site has provision for redundancy measurements, if both instruments (or even all three, where installations are in triplicate) are the same age, it is possible that all will be in a similar condition, presenting a potentially significant issue. Redundancy is only of value where the duplicate device is not subject to the same failure mode as the duty device in the same timeframe.
What do CEM Solutions recommend?
Regular probe maintenance
- Planned routine inspections – including removal of probes
- Leak-checking of probes
Prevention
- Coating probes with an acid-resistant layer
- Using thermal insulation to minimise cold spots
Redundancy planning
- Would a redundant device be best held on the shelf as a spare?
How can CEM Solutions support you?
KAN Developments, and more recently CEM Solutions, have been supplying and servicing O2 probes for more than 30 years.
This includes experience across many manufacturers including:
- Emerson Oxymitter 4000 and OCX 8800
- ABB AZ20
- Fuji ZFK8 & ZKM controller
- Yokogowa ZR22G probe & ZR802G controller
We hold a range of stock spares for the above as well as spare probes.
Contact us today
Get in touch for a quote for a stand-alone site service visit to assess current conditions. We also offer full service & maintenance packages for regular scheduled visits to ensure an accurate and reliable O2 / Oxygen measurement.
Case Study – https://www.cemsolutions.co.uk/project/veolia-o2-analyser-service/
ZFK8 & ZKM Controller
In-Situ Oxygen Analysis System
This in-situ oxygen analysis system eliminates the need for a separate gas sampling device and is ideally suited to combustion control in industrial boilers and furnaces.
It provides a fast response time of four to seven seconds and features HART communication, an easily replaceable zirconia element and a robust IP66 or IP67 enclosure.
Safety features include automatic detector power isolation if a thermocouple burnout is detected, emergency shutdown via an external contact input and a key lock function to prevent operational errors. The ZKMA model can also be operated without opening the enclosure cover.
Oxymitter 4000 & OCX 8800
In-Situ Oxygen Analysis System
These analysers provide accurate, continuous measurement of oxygen and combustibles in flue gases, helping optimise burner efficiency and combustion control.
Features include zirconia sensing technology, field-replaceable sensors, HART communication, optional remote electronics and reduced maintenance through integrated filtration and air purge functions.
AZ20
In-Situ Oxygen Analysis System
The Endura AZ20 provides fast, accurate in-situ oxygen measurement for combustion control and emissions monitoring.
Its robust zirconia probe operates at temperatures up to 800°C and features integrated auto-calibration, HART communication, advanced diagnostics and a fully serviceable design for reduced installation and maintenance costs.
ZR22G Probe & ZR802G Controller
In-Situ Oxygen Analysis System
This analyser provides continuous in-situ measurement of oxygen concentration and humidity in high-temperature gases without the need for a sampling system.
Suitable for boilers, industrial furnaces, dryers and humidifiers, it features touchscreen operation, process diagnostics and reliable control to support improved efficiency and reduced operating costs.
Why choose CEM Solutions?
CEM Solutions was incorporated in 2012, and we specialise in providing business with a range of products and solutions to help meet their emission monitoring requirements.
We now have over 10 years experience in the industry and an ever-growing UK customer base. Our clients are at the core of the services we offer, and we ensure to provide a personal approach that is tailored to your business requirements.
CEM Solutions have a highly skilled team of engineers who are experts in their field and strive to help businesses comply with their emission monitoring regulations.
To discover more about us, or to get in touch with a member of our team, please contact us today with your query and we’ll be happy to assist you.
The benefits of CEM Solutions
Here at CEM Solutions, we have a passionate team that are here to help your business with emission monitoring requirements.
We have the ability to design and install our turnkey solutions which are custom built to your precise requirements. All of the products we use are MCERTS approved and certified. Additionally, we also have a partnership with Dr. Foedisch and are trusted UK suppliers of his industry leading products.
We will consult with you about your requirements, install the equipment and then configure these so they can accommodate your requirements. Additionally, we have 24-hour call-out support on site available should you require our assistance.