Advanced Instruments Inc.

1
Advanced Instruments Inc.

• a business unit of
• Analytical Industries Inc.

2
Management

• Principals
• Frank S. Gregus, President
• Patrick J. Prindible, Vice President
• Mohammad Razaq, Ph.D., Vice President
• Background
• 70 years in field of oxygen analysis
  (Teledyne)
• Design
• Manufacture
• Distribution

3
Why Measure Oxygen ?

• Product quality
• Safety Issues
• Environmental Concerns
• Life Support

4
Oxygen Measurement Ranges

• Engineering Units Analyzer Type
• Pure 100.0 Percent
• Air 20.9 209,000 ppm
  Percent
• 1.0 10,000
  ppm Percent
• 0.1 1,000 ppm
  ppm, Percent
• 0.01 100
  ppm ppm
• 10 ppm
  10,000 ppb ppm
• 1 ppm 1,000 ppb
  ppm, ppb
• 0.5 ppm 500 ppb
  ppm,ppb
  
• 0.01 ppm
  10 ppb ppb

5
Applications

• Industrial Gas Production
• Chemical Process Analysis
• Natural Gas Transmission
• Transportation Storage
• Metals Steel Processing
• Inert gas welding
• Semiconductor Manufacturing
• Electronics Fabrication

Controlled Atmospheres Glove Box Monitoring Area
Monitoring Food Packaging Pharmaceutical
Processing Hyperbaric Diving Environmental Vapor
Recovery Stack Gas Analysis
6
Methods of Measuring Oxygen

• Galvanic Teledyne
• Fuel Cell
• Open Cathode
• Gas Diffusion
• Coulemetric Delta F, Osaka Sanso
• Zirconium Oxide Ametek, Ceramatec,
• Rosemount, Servomex
• Paramagnetic Rosemount, Servomex,
• Siemens

7
Product Development

• Best method also best opportunity
• Service customer needs
• Enhance advantages
• Eliminate limitations
• Broaden the application range

8
Advantages Galvanic Fuel Cell

• Accuracy
• Versatility
• Inexpensive

9
Advantages - Accuracy

• Specific to oxygen
• Excellent long term stability
• Linear output, one point calibration
• Lack of interference

10
Advantages - Versatility

• Adaptable configuration
• Measurement ranges ppb. ppm, percent
• Compatibility with industrial gas streams
• Fast response
• Wide operating temperature range
• Compact size(s)
• Accurate at any constant pressure
• No external power requirements

11
Advantages - Versatility

• Compatible Industrial Gas Streams
• Ambient air
• Inert Gases
• Gaseous Hydrocarbons (-enes, -anes, etc.)
• Hydrogen
• Helium
• Mixed gases
• Acid gases ( 0.5 - 100 CO2 )
• Pure Oxygen

12
Advantages - Versatility

• Inherently intrinsically safe
• Lack of interference from
• Diffusion properties of other gases
• Changes in flow rates
• Particulates
• Moisture
• Position
• Vibration

13
Advantages - Inexpensive

• Manufacturing
• Sample conditioning
• Air Calibration
• Maintenance free

14
Limitations Galvanic Fuel Cell

• Sensitivity below 500 ppb or 0.5 ppm
• Stability at ppb oxygen levels
• Slow recovery from high oxygen levels
• Intolerant to sulfur compounds
• Comparatively short life

15
Limitations - Generic

• Unstable readings related to changing
• Temperature
• Pressure

16
Sensor Principle of Operation

• Sample gas flows into/over/by the sensor and
  diffuses through a Teflon sensing membrane.
• Oxygen in the sample gas dissolves in the
  electrolyte and migrates to the cathode where it
  is reduced by electrons generated by the
  oxidation of the anode.
• Flow of electrons from anode to cathode
  constitutes an electric current proportional to
  the partial pressure of oxygen in the sample gas.
  

17
Sensor Basic Components

• Diffusion barrier ( sensing membrane)
• Sensing electrode ( cathode )
• Counter electrode ( anode )
• Electrolyte ( conductor )
• Body
  ( housing )
• Electrical connections ( to analyzer )

18
Sensor Critical Characteristics

• Stability and accuracy
• Sensitivity
• Speed of response
• Recovery time ( air to 10 ppm )
• Compatibility with background gases
• Operating life
• Operating temperature range
• Maintenance requirements

19
Quality Issues Impact

• Cathode material
• Electroplating
• Electrical connections
• Anode purity
• Electrolyte composition
• O2 trapped by mfg process
• Electrolyte volume
• Electrolyte H2O evaporation
• Anode material volume
• Anode consumption rate

Stability, sensitivity Stability Stability,
life Stability Stability, sensitivity, life (
), compatibility with acid gases Stability,
sensitivity, recovery Life ( ppb, ppm, all XLT
) Life ( ppb, ppm ) Life ( ) Life
20
Analyzer Principle of Operation

• The sample system must present the sample gas to
  the sensor in a manner that enables the sensor to
  perform properly.
• Pressure of 5-30 psig (max 100) enables a
  metering valve to introduce sample gas at
  flowrates 0.1 and 10 liters per minute.
• Signal generated by the sensor is amplified,
  filtered for high and low frequency noise, and
  compensated for signal output variations caused
  by changes in temperature.
• Sample oxygen is displayed by LED or LCD digital
  panel meters.
• Integral circuitry provides 0-1V and 4-20mA
  output signals to external devices and activates
  four alarm relay contacts.

21
Analyzer Basic Components

• Sensor
• Sensor housing
• Sample system ( integral )
• Temperature control heater system ( integral )
• Electronics - amplify, temp comp, outputs, alarms
• Power supply
• Enclosure
• Sample conditioning system ( external )

22
Analyzer Critical Characteristics

• Sensor compatibility with application
• Stability and accuracy
• Response and recovery time
• Configuration
• Electrical power, signal outputs, alarms
• Mechanical sample system, enclosure
• Maintenance requirements
• Installation requirements

23
Application Issues Solutions

• Gas stream composition
• O2 level nominal, min-max
• Compatible gas streams ( std. )
• CO2 and acid gases, corrosives
• H2S and sulfur compounds

• Sensor selection,
• Sensitivity ( range )
• Sample sys. materials,
• Sample conditioning,
• Response time
• Range ppb, ppm ,
• GPR, PSR sensor
• XLT sensor, SS wetted parts, coalescing filter
• XLT sensor, SS wetted parts, H2S scrubber

24
Standard Sensor Application

• Ambient air
• Inert Gases
• Gaseous Hydrocarbons (-enes, -anes, etc.)
• Hydrogen
• Helium
• Mixed gases
• Pure Oxygen

25
Application Issues Solutions

• Operating conditions
• Temperature ( location )
• Pressure
• Particulates
• Dewpoint ( condensation )

• Heater system
• Sample conditioning
• Maintenance
• Installation
• Low - heater system
• High - 10 ft. metal tubing at inlet
• Regulate constant, 100 psi max
• Minor - filter
• Laden - filter, water wash, mixer,
  separator, pump
• Coalescing filter

26
Sample System Basics

• General select materials and components
• that do not contaminate
  sample
• O2 Measurements
• Tygon tubing ( copper recommended )
• SS tubing for corrosive gases
• ppm O2 Measurements ( above 1 ppm FS )
• Brass ( SS tubing ), Swagelock type fittings
• ppb, ppm O2 Analysis ( 500 ppb, 1 ppm FS )
• Stainless steel, Swagelock type fittings

27
Application Issues Solutions

• Area Classification
• General purpose
• Outdoor, dust, water
• Corrosive atmospheres
• Class 1, Div 1, Group B, C, D
• Class 1, Div 2, Group B, C, D

• Enclosure
• 19 rack/panel, wall, 7x 4 panel mounting
  portable
• NEMA 4/12
• NEMA 4X ( fiberglass, SS )
• Explosion proof ( std. flame arrestors Group C,
  D )
• - Remote ex-proof sensor
• Purge System with NEMA rated enclosure
• - Recommend explosion proof
• ( unless cost of purge gas and power is
  not a consideration )

28
Application Issues Solutions

• Outdoor Location
• Electrical connections
• Power requirements
• Output requirements

• NEMA 4/12 enclosure
• Heater system
• ppb, ppm required
• to enhance accuracy
• Stability
• Electrical configuration
• Alarms, Signal Outputs

29
Advantages ppb, ppm Analysis

• Sensor
• 2.5 ppb sensitivity
• 500 ppb FS
• Excellent stability
• Recovery lt 1 hour
• CO2 compatibility
• 12 month warranty
• No maintenance
• Quality

• Analyzer
• Approvals CSA/UL, CE
• Fast start-up bypass
• Metal sensor housing
• Temperature control
• Full sample system
• 4 alarms
• Special configurations
• Cost of ownership

30
Advancements ppb, ppm Sensor

• Quality and reliability
• Proprietary manufacturing process
• Eliminate potential for contamination
• Fewer components of common materials
• Sensitivity, stability and CO2 compatibility
• Proprietary electrodes and electrolyte
• Proprietary manufacturing process
• Warranty and expected life
• Interior design increases volume of electrolyte

31
Advantages Measurements

• Sensor
• Excellent stability
• Fast response
• Longer life 3-5 years
• -30C to 50C range
• CO2 compatibility
• 24 month warranty
• No maintenance
• Quality

• Analyzer
• Approvals CSA/UL, CE
• Sensor housing option
• SS tubing
• Temperature control
• Full sample system
• 4 alarms
• Special configurations
• Cost of ownership

32
Advancements Sensor

• Long life and extended operating range
• Proprietary electrodes and electrolyte
• Interior design increases volume of electrolyte
• Quality and reliability
• Proprietary manufacturing process
• Eliminate potential for contamination
• Fewer components of common materials
• Stability and CO2 compatibility
• Proprietary electrodes and electrolyte
• Proprietary manufacturing process

33
Competition - Micro Fuel Cell

• Specific to oxygen
• Tolerant to dirty sample stream
• Absolute zero, one point calibration
• Excellent long term stability
• Compact
• Inexpensive
• Limited sensitivity
• Slow recovery from high oxygen levels
• Inconsistent performance
• Shorter life, prorated warranty
• Intolerant to sulfur compounds

• Advantages
• Disadvantages

34
Competition - Open Cathode
Advantages Disadvantages

• Advantages

• Sensitivity to 5 ppb oxygen
• Fast response and recovery
• Excellent long term stability
• Absolute , one point calibration
• Inexpensive
• Sensitive to shock
• Intolerant of particulates
• Continuous electrolyte addition
• Maintenance intense sample system
• Intolerant to sulfur compounds

35
Competition - Coulemetric

• High sensitivity
• Longer life ( non-depleting )
• Linear output , one point calibration
• Good stability
• Recalibrate for diffusion rate of gases
• Recalibrate for inherent drift
• Flow sensitive, expensive sample system
• Slow recovery from O2 upset in ON position
• Requires electrolyte every 6-8 weeks
• Requires clean sample stream
• Sensor replacement cost 3,500

Advantages Disadvantages
36
Competition - Zirconium Oxide

• Fast response and recovery
• Longer life ( non-depleting )
• Interference from reducing gases H2, CO, HC
• 1,110-1,470F required to conduct ions
• Drift due to stability of electrodes
• Sensitive to pressure changes
• Intolerant to particulates, sulfur compounds
• Initial expense - sensor, furnace, electronics
• Ongoing expense - reference gases, power, sample
  conditioning, sensor replacement

Advantages Disadvantages
37
Competition - Paramagnetic

• Excellent stability for 99-100 analysis
• Insensitive to sulfur compounds
• Lacks sensitivity below 1 oxygen
• Sensitive to temperature, changes in flow,
  position, vibration, particulates, moisture
• Drift 4 of full scale per week
• Expensive complex sensor
• Expensive sample conditioning required
• Expensive installation and maintenance

Advantages Disadvantages