There are several Virtual Analysers already serving the process industry. Below is an example of virtual oxygen analyser, how it works and the benefits it offers over a conventional hardware analyser which include:
- Higher reliability
- Not prone to drift
- Lower operating & maintenance cost
- No calibration, zero or span checks
- Lower capital cost for installation
- No hardware required for installation
In a process plant, the O2 analysers are installed on combustion sources e.g. a boiler or a reformer.
For this particular example, we will consider the example of a steam generating boiler. Most combustion sources have any or all of the following sensors & analysers, as applicable:
- Ambient temperature
- Boiler feed water flow rate
- Boiler feed water valve opening
- Combustion air damper position
- Combustion air flow rate
- Firebox temperature
- Flame sensor
- Fuel flow rate
- Fuel gas pressure
- Induction fan motor amps
- Steam turbine rpm
- NOx analyser
- O2 analyser
- Steam flow rate
- Steam pressure
- Steam temperature
The data from available sensors is fed into the VAS (Virtual Analyser System) which “learns” the operating parameters throughout the entire range of operation.
Usually a few weeks of operating data before & after a shut down is enough for the VAS to predict the O2 content with +/-5% accuracy. It improves to +/-2% over time as more and more operating data is obtained.
The VAS gets fully trained in almost one year when four seasons have passed. After that, the VAS can give early warning for the failure or problems of:
- Boiler tube health
- Damper problems or failure
- Sensor drift of all sensors
- Optimum timing for calibration of all sensors & analysers
Traditional hardware analysers can’t do any of this. You can Contact Us for a demo install of our O2 VirtuaLyser at your site.