Detect the type of industrial gas analyzer system
Selecting the appropriate detection technology is crucial when integrating a gas analyzer into an industrial process. Various technologies are available, including infrared (IR), thermal conductivity (TCD), zirconium oxide (zirconia), and paramagnetic detection for oxygen measurements. Each technology has its own advantages and disadvantages, making it important to choose the one that best suits your specific application. 
Is it In-Situ or Extractive?
In-situ gas analyzers are installed directly in the process stream, measuring gas concentration on-site and in real-time without moving or altering the sample. This makes them more efficient in terms of response time and typically more compact and energy-efficient, as they do not require gas preparation before analysis.
Extractive gas analyzers, on the other hand, take a sample of the process gas and analyze it outside the process at a certain distance. This method has a longer response time and requires a sample collection and processing system. Both methods have their advantages and disadvantages, and the best choice depends largely on the specific application.
Inspect the design of the gas analyzer sampling system
When developing gas analysis solutions, it is crucial to consider the design of the sampling systems, also known as sample processing or conditioning systems. The sample gas must accurately represent the process gas and be free from solid, liquid, or gaseous contaminants that could damage the sensor. Additionally, the sample gas must be delivered to the analyzer at a specified and consistent flow rate and pressure. Depending on the application and detection technology, different types of sampling systems may be required. For example, most IR analyzers operate at room temperature, so the gases must be dried beforehand to prevent condensation in the analyzer’s cell. However, an analyzer equipped with a heated cell for measuring soluble compounds will receive hot, pre-filtered gas.
Adapt the industrial gas analyzer to its environment
The industrial analyzer must be designed to function and endure the challenges of environmental conditions, such as high temperatures, pressures, and vibrations. The main questions to address at this stage include:
- Will the gas analysis system be installed outdoors, indoors, or under cover? This will determine the cabinet’s protection level as well as the need for air conditioning and/or heating
- How much space is available for the system? Should it be wall-mounted, standalone, or housed in a bungalow?
- Will the equipment be installed in an ATEX zone? If so, what type of zone? This is critical not only for selecting and integrating components but also for calculating the project budget during the initial planning phase
Know the interface of the industrial gas analyzer
The primary function of an industrial analyzer is to determine the concentration of gas components in an industrial process. Its purpose, however, is to inform the user or even control the process.
For a Continuous Emission Monitoring System (CEMS), the analysis system will be equipped with automated Data Acquisition and Handling System (DAHS) software. This software serves as a specific and complex interface, complying with standards such as EN14181 for CEMS and EN17255 for DAHS.
For analysis systems employed in overseeing industrial processes like combustion control or heat treatment furnaces, measurement data along with pertinent status details (ranges, alarms, etc.) are relayed to the control system via analog signals (e.g., 4-20mA, relay contacts) or through digital transmission protocols (such as Modbus, Profibus).
Depending on user preferences, a range of devices including PCs, industrial HMI touch screens, smartphones, or tablets can serve as interfaces.
Understand the accuracy of the industrial gas analyzer system and its durability
The final critical aspect to evaluate is the durability and performance of a gas analysis solution. The system must endure rigorous industrial conditions while retaining its accuracy over time. To sustain the accuracy of a gas analyzer, three fundamental design factors must be considered:
Firstly, a calibration device should be integrated into the sampling system. Ensuring ease of calibration is crucial, whether through a manual device or an automatic calibration system. Additionally, it should accommodate the calibration frequencies necessary for both the detection technology and the operator’s requirements to guarantee measurement accuracy.
Components like seals, filters, and pump valves should be conveniently accessible to facilitate routine maintenance tasks. Operators can receive training for these maintenance procedures, or maintenance can be outsourced. All materials utilized in gas analysis systems, whether inside the gas analyzers or within the sampling systems, must be compatible with the sample gas conditions. They must exhibit resistance and inertness to withstand moisture and corrosion. This not only safeguards analytical equipment from damage but also ensures that gases remain unaltered prior to analysis.
