Test Analyzer
Test Analyzer
Furnace Oxygen Test?
At work we use a Flue Gas Analyzer to test the oxygen level in our furnace when the burners are on high fire. The oxygen levels when firing at an 85% firing rate should be within 2-3% range. This equates to a 10-15% excess air range. I was just wondering if there is another way to test the oxygen level? Maybe by some equation?
Testing Oxygen in Flue Gas :
The pioneer of combustion efficiency testers is the Orsat analyzer, a chemical testing apparatus in which flue gases are mixed with a liquid reagent that changes volume as a result of the reaction. The apparatus displays the volume change accurately, providing an accurate indication of combustion efficiency. Oxygen, carbon dioxide, carbon monoxide, and other gases can be analyzed.
The Orsat analyzer is simple and accurate. A portable version is available at moderate price. However, the apparatus is built of delicate glass tubing and requires a fine touch. Modern testers are much more rugged and much easier to use, so the Orsat analyzer is now a museum piece.
A similar chemical approach is used by the vintage Bacharach “Fyrite” tester, which is compact and made of plastic. One version of this unit tests for oxygen, and a different version tests for carbon dioxide. They are shown in Figure 3. The “Fyrite” is less accurate than the Orsat, but it is rugged and fairly easy to operate. It is the least inexpensive of all combustion gas analyzers. You need to read a table to use this device. These testers require replacing their chemicals after a certain number of tests, and the chemicals have a limited storage life.
In recent years, electronic testers have become available for analyzing flue gases. Some typical units are shown in Figure 4. Most electronic testers use an electro-chemical cell as the gas sensing element. A different cell is required for each gas being measured.
The most common sensor used in oxygen testers is a zirconium oxide element that develops a voltage difference across two sides if there is a difference in oxygen concentration. The zirconium oxide element has the advantage that it can be exposed to flue gases for thousands of hours.
The rubber hose draws a flue gas sample through a liquid in the tester. A chemical reaction changes the liquid volume, revealing the amount of gas.
Electronic flue gas analyzers : These test for a variety of gases. Oxygen and carbon dioxide testers can calculate combustion efficiency directly.
The overwhelming advantage of electronic testers is that they provide an immediate and continuous readout simply by inserting a probe into the flue gases. This allows you to see the effect your of boiler adjustments immediately.
Some combustion efficiency testers avoid the need to use a table to calculate efficiency. They perform the efficiency calculation with a microcomputer and read out combustion efficiency directly. There is a potential for error with such testers because efficiency depends on the temperature of the inlet air as well as the temperature of the flue gas. Some testers use the temperature of the air surrounding the tester as the inlet air temperature. This introduces error because the air near the flue may be much warmer than the air entering the boiler. Better testers provide a separate remote thermometer for measuring the air inlet temperature while you take the flue gas sample.
Electronic testers of good quality are substantially more expensive than chemical testers. Still, the price is small compared to the benefit of keeping boiler efficiency optimized (unless your boilers are very small). As with most electronic equipment, the quality of electronic flue gas analyzers varies widely. The best of the lot may be capable of better accuracy than the inexpensive chemical testers. The worst of the lot are incapable of providing useful accuracy.
A weakness of all electronic gas analyzers is that they must be re-calibrated frequently because the sensor output drifts. Fortunately, oxygen testers may be self-calibrating by using the oxygen content of the atmosphere as a calibration point. Testers for other gases require calibration using pre-mixed gases. Since the inner workings of these instruments are invisible, calibration is an act of faith in the calibration gases.
Most inexpensive electronic combustion analyzers do not measure carbon dioxide directly. Some units provide a carbon dioxide reading, but this is derived by internal calculation from the oxygen measurement. If you want to use a carbon dioxide test to check the oxygen test, a value that is calculated from the oxygen measurement is useless. Measure carbon dioxide with a separate instrument designed for that purpose
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