Manual versus Digital Flue Gas Analysers

Manual wet combustion testing kits for oil-heating appliances were bulky, susceptible to inaccurate readings, cumbersome, time consuming to operate and contained chemicals that were potentially dangerous to humans. The visual impact of the kit today would leave a customer, and indeed a heating professional, feeling a little apprehensive in view of its ‘archaic’ qualities.

However, in view of the modern professional digital gas flue analyser accompanied by its infra red thermal printer, a heating professional can connect his or her flue gas analyser to the heating appliance flue, monitor the data from the equipment and simply adjust burner components to acquire the required result within seconds of making that adjustment.

Fuel Economy and the Environment

With today’s higher heating fuel prices and depleting natural resources, the flue gas analyser is essential for maintaining fuel economy whilst reducing carbon and toxic emissions into the environment. Customers can now expect a shorter service time with combustion test results printed out immediately and attached to the heating appliance service record within minutes.

Through the use of the latest flue gas analysis equipment, the heating professional requires less service area to work in that helps maintain a cleaner environment within a customer’s property when compared to previous methods of heating appliance combustion testing.

Flue Gas Analyser Calibration and Servicing

Periodic servicing and calibration of digital flue gas analysers is essential. With the wide use of the flue gas analyser throughout the professional heating industry, the cost of servicing and calibrating a unit has seen a substantial fall in recent years. These costs will probably continue to fall, as more heating professionals realise the value and consequently the requirement of a digital flue gas analyser during installation or servicing of heating appliances.

Gas Service Engineer Competency

In 2010, it will be a requirement for all United Kingdom gas service engineers who install and service certain gas heating appliances to certify their knowledge in the correct use of a flue gas analyser. The CPA1 Combustion Performance Analysis of Domestic Appliances is a course and assessment intended for gas service engineers who employ combustion analysis as an essential element of the installation, commissioning, servicing and maintenance of a gas heating appliance, that is listed in BS7967 Part 3 2005 Guide, and to take appropriate action in respect of measurements obtained from a flue gas analyser.

In essence, the digital flue gas analyser is a boon for all heating professionals as it provides a customer with confidence and trust in their proficiency whilst in the knowledge that their heating appliance is operating effectively, safely and efficiently.

The Modern Digital Flue Gas Analyser is from Flue Gas Analyser

The specific content of flue gases depend on what particular type of fuel is used and how it is combusted will determine the constituents of the flue gases released. For example, a poor combustion process running at low temperatures with a poor air supply will invariably produce more pollutants than a combustion process with the correct combustion control factors of fuel delivery, ignition and air supplies etc. These are several reasons why a serviceable flue gas analyser is essential in realising the composition of flues gases within the combustion process of a heating appliance.

In essence, flue gases are the by-products of combustion and the combustion process determines their ultimate make up.

That said, flue gas or gases will primarily consist of uncombusted nitrogen taken from primary and/or secondary combustion air supplies, water vapour (H2O) created by the combustion of hydrogen in the fuel with oxygen (O2), also taken from primary and/or secondary air supplies, excess oxygen, again also taken from primary and/or secondary air supplies and carbon dioxide (CO2) which is the result of carbon from the fuel combined with oxygen.

Water Vapour

People often mistake the white plumes seen coming from flue terminals, as ‘smoke’ but is in fact water vapour condensing, as it comes into contact with cool air. These plumes are also more evident from heating appliances that use condensing heat exchangers, which recover more heat from the flue gases that would otherwise escape into the atmosphere. As of result of this action, the flue gases become a lot cooler and appear as water vapour in higher ambient temperatures when exiting the flue.

Flue gases will also contain smaller amounts of pollutants such as nitrogen oxides (NOx), sulphur oxides (SOx), carbon monoxide (CO) and particular matter derived from the substances contained in the fuel itself.

Nitrogen Oxides

Nitrogen oxides are highly toxic and are obtained from the nitrogen within the primary and/or secondary air supplies and from materials contained within the fuel. Heating appliances emitting significant amounts of nitrogen oxides will often cause irritation to the eyes.

Sulphur Oxides

The main source of sulphur oxides is the burning of fossil fuels. Sulphur oxides dissolves within water vapour in the air to form acids, and interacts with other gases and particles in the air to form particles known as sulphates and other products that can be harmful to humans and the environment.

Carbon Monoxide

Carbon monoxide is a tasteless, odourless, colourless and poisonous gas caused by incomplete burning of carbon-based fuels during a poor combustion process. Carbon monoxide accounts for most fatalities associated with flue gases from heating appliances.

The constituents of flue gases are within the control of the heating professional. As one of his or her primary responsibilities, the heating professional must be fully conversant with principles of the combustion process to overcome any potential problem associated with poor combustion performance of a heating appliance. Consequently, the use of a serviceable flue gas analyser is a fundamental measuring instrument for all who service, maintain and install fossil fuel heating appliances.

Flue Gases and the Serviceable Flue Gas Analyser is from Flue Gas Analyser

During the past 10 years, gas analysers have become a vital part of every heating professionals’ tool kit. Today’s electronic instruments are multifunction in their operation, enabling gas escape detection, temperature, pressure and carbon monoxide (CO) environmental monitoring as well as analysis of flue gases. These functions can help to assist in completing forms such as landlord certificates, gas safety certificates and Benchmark commissioning checklists.

Due to recent changes in the building regulations, there are now over 7.8 million high efficiency appliances installed in the United Kingdom with a further 1.5 million being fitted each year. These changes have made it more important to use a flue gas analyser as part of the day-to-day working practice of a heating professional.

The Gas Safe Register announced just under a year ago that all registered gas engineers who have or due to gain ACS modules CEN1 or HTR1 now require the flue gas analyser qualification CPA1. Those gas engineers who do not hold the CPA1 qualification after 1st April 2012 will have their CEN1 and/or HTR1 suspended.

British Standards such as BS 6798, BS 7967 and BS 5871 Part 1 state the requirement to use a flue gas analyser when maintaining and servicing particular heating appliances. The CPA1 Combustion Performance Analysis of Domestic Appliances assessment is intended to provide gas engineers with the essential knowledge of correctly using a flue gas analyser.

There are numerous professional instruments on sale, which are made by several different manufacturers that include Kane, Telegan, Testo and TPI but heating professionals should select an instrument that is capable of measuring all combustion gases and appropriate pressures to make sure that a heating appliance is working safely and efficiently.

Monitoring the products of combustion will ensure a heating professional has the ability to precisely control levels of carbon monoxide (CO), oxygen (O2), the ratio of carbon monoxide and carbon dioxide (CO/CO2), excess air and flue gas temperature.

When testing a gas installation for soundness, many instruments have the facility to measure pressure enabling a let by/tightness test. The temperatures of flow and return water can also be monitored using a suitably equipped flue gas analyser making commissioning of a heating appliance considerably easier.

Another unique feature of today’s professional instrument is to monitor ambient carbon monoxide levels that will inform the heating professional as to the amount of CO at each given minute during a test period.

Gas Engineers Will Require CPA1 From 1st April 2012 is from Flue Gas Analyser

A smoke test can be accomplished using a smoke test pump and filter paper. To prevent condensation of the flue gases, first warm the smoke test pump body. To obtain a sample of flue gas, insert a clean piece of filter paper into the smoke test pump slot and tighten the clamp.

Take a Sample of the Flue Gases

After the heating appliance has been operating for approximately ten minutes, place the sampling tube of the pump into the test point on the heating appliance flue whilst been careful not to make contact with the internal surfaces of it. This could cause carbon deposits (soot) to enter the sampling tube and produce a smoke spot that provides an incorrect reading.

Check the Smoke Count

Pump the smoke test pump evenly ten times to obtain a sample of the flue gases through the filter paper. Remove the filter paper and compare the smoke spot produced on the filter paper with the smoke count chart provided with the pump. Adjust the burner’s air damper so a smoke count of no more than two is obtained and repeat the test until the desired result is achieved.

Water Vapour Present

If the air damper on the burner is opened excessively then this may produce a wet spot on the filter paper. This wet spot is caused by water vapour within the flue gases that is caused by too much excess air. Simply reduce the amount of air and re-test until there is only a trace or a smoke count of one is achieved.

Consult Manufacturer’s Data

If in the event that the smoke count will not reduce then, if possible, observe the burner flame for instability, misshape or impingement. Recheck the burner’s oil pump pressure against the burner manufacturer’s data and if necessary, replace the burner nozzle with a new burner nozzle to the correct spray angle, flame pattern and output as indicated by the burner manufacturer.

After a satisfactory smoke test, a flue gas analyser can now be used to complete the combustion efficiency testing of the heating appliance.

Electronic Smoke Test Pump

The manual measurement of a smoke count using a smoke test pump, as described above, can be complicated and time consuming. However, with the introduction of the electronic Testo 308, this process has become faster whilst not compromising the accuracy of a smoke test. This instrument will definitely compliment the range of tools, including the flue gas analyser, used by a heating professional in the oil-fired heating appliance industry.

Smoke Test before using a Flue Gas Analyser is from Flue Gas Analyser

Safe Operation of a Heating Appliance

Alarmingly, it is becoming a quite common story of deaths caused by carbon monoxide (CO) poisoning because of incorrectly operating or dangerous conditions of heating appliances within dwellings. Therefore it is imperative that gas service engineers are able to competently check the safe operation of a heating appliance after installation or during a service call. This has led to the government to legally require that all gas service engineers are certified in the understanding the proper and safe use of a flue gas analyser.

Operating a Flue Gas Analyser Effectively

Unfortunately, a vast majority of gas service engineers are unaware of the full potential that a flue gas analyser has to offer or indeed how to operate the equipment effectively – a common mistake is simply failing to select the required operating mode on the flue gas analyser for a particular type of fuel. From February 2010, all gas service engineers completing or holding HTR1 and CEN1 will be legally compelled to complete their CPA1 first.

CPA1 Course and Assessment

The Combustion Performance Analysis of Domestic Appliances course and assessment comprises of:

• Commissioning, servicing and testing appliances requirements when new components have been installed
• The Gas Industry Unsafe Situation category given to gas appliances that do not reach a satisfactory combustion performance
• Allowances made for gas cooker carbon monoxide (CO) levels
• Comprehension of action levels for gas appliances
• Remedial action required if carbon monoxide (CO) / carbon dioxide (CO2) ratio levels continue to be above suitable performance levels after adjustment

With the introduction of the CPA1 flue gas analyser assessment course, which is ratified by the Approved Certification Scheme (ACS), both the government and the heating industry have implemented necessary action to provide gas service engineers with a thorough understanding of combustion performance gas analysis required for commissioning at installation, re-commissioning after servicing or replacement of parts or the recognition of full service requirements on gas-fired appliances listed in BS 7967 Part 3 2005 Guide.

CPA1 Combustion Performance Analysis of Domestic Appliances is from Flue Gas Analyser

Listed below are some of those critical factors:

• Get to know the flue gas analyser. Study the product manual to thoroughly familiarise yourself with the flue gas analyser functions and any peripherals (printers etc.) before using it.
• Ensure any rechargeable batteries within the equipment are fully charged before arriving at the service site.
• Ensure that any mains power supply is undamaged and ready for use before arriving at the service site.
• Check to see if any printer has sufficient paper before arriving at the service site.
• Never expose the equipment to moisture, fuel oils and chemicals as this may seriously affect the operation of the flue gas analyser.
• Ensure that the correct fuel type is selected on the flue gas analyser for the type of fuel used.
• Avoid using the flue gas flue analyser for long periods or during freezing temperatures, as this may limit the life of the internal sensors.
• Use the equipments backlit display facility during poor lighting conditions to avoid inaccurate readouts.
• Ensure that any condensation (water) trap is frequently emptied to maintain optimum performance and to help prevent equipment damage.
• Try to avoid leaving the flue gas analyser unattended when in use to help prevent any external interference.
• Clean the heating appliance, its components and the immediate service area first before using the flue gas analyser.
• Always perform a smoke test on oil-fired heating appliances before using a flue gas analyser to prevent damage to the equipment’s internal sensors.
• Avoid kinking or damaging sensor tubes, probes and thermocouples, as this will severely compromise the operation of the flue gas analyser.
• If fitted, always leave the flue gas analyser within its protective boot jacket when in use.
• Never use the analysis equipment and/or its probes on or near live electrical components.
• The flue gas analyser should be stored securely in its carry case when transporting to and from the service site and when not in use.
• When in use, attach the flue gas analyser to the heating appliance casing using its magnetic boot jacket to keep it out of harms way when making adjustments to burners etc.
• Always follow manufacturers instructions and recommendations for servicing and maintenance of the flue gas analyser.

Critical Factors to Consider Before Using a Flue Gas Analyser is from Flue Gas Analyser

The safety issues surround the installation of boilers fixed to internal walls in properties where the flue is directed through an area containing a void, for example, a vertical flue passing through a ceiling into the floor area above and no inspection cover is installed. Since this hidden part of the flue cannot be properly inspected, a compromised flue in the void area may release significant amounts of products of combustion, including carbon monoxide, into living or sleeping areas, which could be lethal to residents.

With progression of technology during the last decade, manufacturers of heating appliances can now provide installers with longer lengths of flue gas discharge pipe work that can also turn in several directions. Although the Gas Safety (Installation and Use) Regulations 1998 places a legal duty on all landlords to check the fittingness and effectiveness of a heating appliance flue, residents are often unaware of the path and direction of flues concealed in voids and may mistaken staining on a ceiling surface that is caused by products of combustion and/or flue condensate, as a water or grease stains and more so when the boiler is located in a kitchen.

Emphasis has been put on notifying residents, particularly those who own or rent flats and apartments that were constructed or refurbished between 2000 and 2007, of these safety concerns through various initiatives including newsletters, trade talks and meetings. New buildings constructed over this period could also be identified using the house stock database which will help the industry provide a means of inspecting the properties for possible safety concerns and install appropriate inspection covers that comply with relevant standards and current regulations.

Obviously, every heating professional who services and maintains gas boilers are in a unique position to identify flues that are concealed and take the necessary action to remedy the problem. From the data collected, heating professionals will also be able to identify a pattern that may exist on a particular housing estate giving a clear indication that other properties on the estate might be at risk from the same problem. As a further precaution, heating professionals should also carry out an ambient carbon monoxide build up test using a flue gas analyser in all habitable areas where the flue passes through to ensure dangerous carbon monoxide levels are not present when the heating appliance is operating.

Safety Issues Concerning Flues In Hidden Voids is from Flue Gas Analyser

It is widely understood that to complete a gas safety inspection, it would not be possible to do so without the use of an electronic analyser. However, The Gas Safety (Installation and Use) Regulations 1998 does not stipulate the use of flue gas analysers.

The charity and the plumbing company have branded the current regulation as ‘madness’. Managing Director of Pimlico Plumbers, Charlie Mullins, stated: “The current regulation is madness and puts so many people at risk. It is total common sense to clarify the regulations and make this equipment mandatory. At the moment it’s like sending a soldier into a minefield without a mine detector.”

Mr Mullins business is paving the way forward and hopes to set an industry standard by supplying all of his Gas Safe registered engineers with flue gas analysers, which surpass the requirements of the 1998 Regulations.

President and Director of CO-Gas Safety, Stephanie Trotter, called for a change in the current legislation during the launch of the All-Party Parliamentary Gas Safety Group at the House of Lords, where Mr Mullins company was also present.

Mr Mullins said: “The reaction from the cross-party parliamentary group to our calls was positive, but I am not waiting around for any changes. By giving my engineers the analysers, we are adding to their safety and the safety of the people using the gas appliances they inspect. We are drawing a line in the sand to say this is how gas inspections should be carried out and hope the rest of the industry follows our lead.”

Ms Trotter also stated: “Since 1995, nearly six hundred people have died that we know about from carbon monoxide poisoning and we know we only see the tip of the iceberg. It is ridiculous that a gas safety check does not require the use of equipment to test appliances from this invisible killer.”

Plumbers And Charity Call For Mandatory Use Of Flue Gas Analysers is from Flue Gas Analyser

Starting in July 2010, HETAS and OFTEC will begin collecting information relating to all carbon monoxide incidents in their relevant industries that will be included on the Gas Safety Trust’s Carbon Monoxide Report, which will be available in October 2011. OFTEC’s Inspection and Service Manager, Mr Adrian Lightwood, said: “Its findings will provide an important benchmark against which we can compare the numbers and causes of carbon monoxide incidents in the future.”

Gas Safety Trust Manager, Mr Nigel Dumbrell stated: “Our partnership with OFTEC and HETAS represents a huge step towards understanding and reducing carbon monoxide incidents nationwide. For the first time, we will be able to assess more effectively the causes of carbon monoxide incidents across all fossil fuels used for heating and cooking in the home environment. In particular it will enable us to evaluate more comprehensively the issues of most concern and especially those individuals most at risk.”

New Partnership To Help Reduce Carbon Monoxide Incidents is from Flue Gas Analyser

The Sprint V2 Kit 3 also includes an extra probe kit to sample flue gas emissions from flueless appliances, cookers and grills, as outlined in BS7967:2005 and CPA1, in addition to a gooseneck gas escape probe that comes with a ultra bright light emitting diode (LED) searchlight.

To simplify let by & tightness testing by enabling the heating professional to get the desired gas pressure on their manometer without having to keep removing the manometer hose and making repeated adjustments, the kit also includes an APRV Anton Pressure Relief Valve.

Ultimately manufactured to help heating professionals in the safe installation, commissioning and servicing of gas heating appliances, the Anton Sprint V range offers 5 instruments in one compact and practical handheld unit consisting of a basic Sprint multifunction flue gas analyser, a differential manometer, a differential thermometer, a carbon monoxide room safety monitor and a gas leak detector.

New Anton Telegan Flue Gas Analyser Kit Meets Requirements is from Flue Gas Analyser