Project Details
Gas Analysis Equipment Installation at a Pohang Manufacturing Facility: FIX800, Preprocessor, and Portable Detectors
A Pohang-based manufacturer required measurement and analysis of gases generated during material combustion testing processes. Following multiple rounds of technical consultation, site assessment, and a direct on-site meeting to discuss application-specific limitations, RS Korea supplied and installed a combined system of fixed-type gas analyzers (FIX800), gas sampling preprocessors for moisture and temperature conditioning, and portable multi-gas detectors. The total order comprised 4 sets of portable equipment, 3 sets of fixed installation equipment, and full construction services completed in approximately three hours.
Installation Specifications
| Item | Details |
|---|---|
| Fixed analyzers (portable) | GASTIGER 2000: CO₂ 0–100% × 1 unit; GASTIGER 6000: O₂ 0–25% / SO₂ 0–10,000 ppm × 1 unit; GASTIGER 6000: CO₂ 0–100% / O₂ 0–100% × 1 unit; GASTIGER 6000: SO₂ 0–10,000 ppm × 1 unit |
| Fixed analyzers (installed) | FIX800: F₂ 0–100 ppm / Cl₂ 0–200 ppm / CO₂ 0–50% × 1 unit; FIX800: CO 0–10% × 1 unit; FIX800: SO₂ 0–10,000 ppm × 1 unit |
| Preprocessor | Gas sampling preprocessor for moisture removal and temperature control; 3 FIX800 units consolidated into 2 preprocessor enclosures to optimize space and cost |
| Sampling line & installation | IN/OUT sampling ports drilled and welded onto ~2 m discharge piping (SUS 304 socket weld); PU (polyurethane) tubing for sampling line; cable tray and existing steel conduit used for power wiring; ball valves installed for future maintenance isolation |
| Installation location | Pohang, North Gyeongsang Province, South Korea — manufacturing R&D facility |
Key Technical Considerations for Combustion Gas Measurement with Electrochemical Sensors
- Standard fixed-type electrochemical gas detectors are designed for industrial safety monitoring of ambient air; they are not optimized for direct measurement of high-concentration combustion exhaust gases without sample conditioning.
- When measuring high-temperature combustion gases (containing NO₂, SO₂, Cl₂, F₂, CO, CO₂), cross-interference between target gases can cause sensor readings to be over- or under-reported, affecting measurement accuracy.
- A gas sampling preprocessor — incorporating moisture removal and temperature reduction — is essential to protect sensor elements and extend sensor lifespan when sampling from exhaust ducting.
- The application environment (fuel composition, particulate loading, temperature range) must be clearly defined prior to equipment selection; undefined dust levels and fuel variability increase the risk of premature sensor degradation.
- Following thorough technical disclosure of these limitations, the end customer confirmed acceptance of the operating constraints and proceeded with the order, with standard gas injection testing confirming rapid sensor response and satisfactory performance upon commissioning.
Frequently Asked Questions
Can standard industrial gas detectors be used to measure combustion exhaust gases directly?
Standard fixed-type electrochemical gas detectors are designed for industrial safety and ambient air monitoring. Measuring combustion exhaust gases directly — without a preprocessor — is not recommended, as high temperatures, moisture, and particulate matter can damage sensors and degrade measurement accuracy. A gas sampling preprocessor that conditions the sample (cooling, drying, filtering) is required for reliable operation in combustion exhaust environments.
What is a gas sampling preprocessor, and why is it needed with the FIX800?
A gas sampling preprocessor draws sample gas from the source, removes moisture and reduces temperature to levels safe for the sensor, and delivers a clean, conditioned sample to the detector. In this Pohang installation, three FIX800 units were served by two preprocessor enclosures (rather than one per unit) to reduce space requirements and system cost while maintaining effective sample conditioning.
What gases were monitored in this installation, and what are typical measurement ranges?
The fixed FIX800 analyzers covered F₂ (0–100 ppm), Cl₂ (0–200 ppm), CO₂ (0–50%), CO (0–10%), and SO₂ (0–10,000 ppm). The portable GASTIGER units covered CO₂ (0–100%), O₂ (0–25%), and SO₂ (0–10,000 ppm) for supplementary and mobile measurement tasks during the combustion testing process.
How are sampling lines and wiring protected in a harsh industrial environment?
In this project, PU (polyurethane) tubing was selected for the sampling lines due to its chemical resistance and flexibility, facilitating future maintenance access. Power supply wiring was routed through existing steel conduit for mechanical protection. SUS 304 stainless steel socket welds were used for the IN/OUT penetrations on the exhaust ducting, with ball valves installed at each port for safe isolation during inspection or servicing.
#FIX800 #GASTIGER #CombustionGasMonitoring #GasPreprocessor #SO2Detection #Pohang #IndustrialGasDetector #WANDIKorea
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