‘’We asked 100 Service engineers to name the five most common failures they were likely to see on a CEM system!’’ Well, not exactly, but we did ask our own service team to individually name the top five failures that they might expect to see. The results are as follows:
1. External Factors
The diplomatic way of saying things that are outside of the CEM system itself; poor plant air (oil + water), an unreliable power supply or third-party intervention introducing a crazy calibration!
These are just the observations of our CEM Solutions Service team, drawing on our collective experience across many different systems and applications.
What was quite evident when I analysed all of our answers (submitted separately with no conferring!) is that none of our engineers flagged analysers up in their five most common failures. Having been in this industry for some years, I do wonder if the answers may have been different had the same question been posed 20 years ago.
When designing a CEM system built to last there should always be particular considerations for the seemingly ancillary items and not just the analyser; the materials used for the pump heads and solenoids; the capacity of the chiller systems; the IP rating of the panel etc.
2. Leaks
The reverse issue to blockages! These proved to be the most popular failure point amongst our engineers – and one that can slip past an unobservant eye! After all a leak can be tiny – this will however still have a detrimental effect on the performance of the device.
QAL3 checks can be a good way of flagging up potential leaks, subject to the QAL 3 being performed locally via a probe and the results being sufficiently interrogated.
3. Blockages
These are not always at the sample probe; they can also be NOx converter cartridges, cold spots either on a sampling system (salts dropping out of a sample) or on concrete stacks on the sample tube itself.
We have improved many existing systems, including adding pre-filters, blow-back systems, heated connections and improved insulation. In a few cases where a CEM system has been poorly specified from the outset, we have had to replace the whole system.
4. UV Degradation of Heated Sample Lines
Unprotected plastics don’t like excessive exposure to sunlight as it tends to make them very brittle.
We offer a UV protective sheaf on our lines to increase their service life – It is an avoidable and often costly exercise replacing lines and with a small additional outlay, their service life can often be more than doubled.
5. Moisture/Contamination
Failure of several different components can have the same effect and so it perhaps is no surprise that this makes the top five.
Faulty peristaltic pumps or chillers, frozen drains or an inadequate condensate discharge capacity are just some of the potential causes. Our systems always have a moisture interlock and alarm to prevent any knock on damage and the MGA12 and 20 both measure moisture, enabling a continuous status check on the conditioning device without the need for an auxiliary device. Of course, hot-wet systems such as the MCA10 don’t face such challenges as they measure the gas in the pre-conditioned state.
Suitably robust sampling systems are essential to ensure the long-term reliability of CEM installations – ensuring less call-outs to site, value for money across the life of the CEM system and making the life of operators and service engineers alike easier all round! Find out more about our Servicing & Calibration services.
If you have CEM system failure or issues, then please contact us today to see how our team of experts can help your business.