26 | Plant & Works Engineering www.pwemag.co.uk February/March 2026 Energy & Environmental Management Focus on: Boilers, Burners & Controls Gas analysis technology has evolved significantly since the late 1970s, when component consistency and sensor stability were more limited and instruments required closer maintenance oversight. Advances in electronics, materials and sensor design have since improved performance expectations across the sector. James Clements, Managing Director of Signal Group, who has over 23 years of experience in gas analyser design, notes that reliability remains a common concern. He reports that organisations often seek assistance after encountering performance issues with existing analysers. “In many cases, manufacturing or processing facilities are simply unable to operate when a gas analyser malfunctions,” he explains. “This might be because the analyser performs a regulatory compliance function, or that it provides essential measurements for process control.” In combustion systems, including boilers and industrial burners, gas analysis data is critical for maintaining correct air-to-fuel ratios, optimising efficiency and demonstrating emissions compliance. Where analysers are integrated into control strategies, inaccurate readings can result in poor combustion performance, excess fuel consumption or unnecessary plant trips. The financial consequences of unreliable measurement can be significant. Beyond lost production, organisations may face product waste, contractual penalties and the costs associated with restarting complex thermal processes. Sources of error Sampling errors are among the most common causes of unreliable readings. For accurate analysis, samples must be representative of the process stream and remain so throughout transport to the measurement cell. Particulates must be removed effectively, filters maintained, and sampling lines designed to prevent condensation. Moisture ingress can damage instruments and allow soluble gases to dissolve before measurement, distorting results. Calibration practices are another critical factor. Inaccurate readings can result from extended calibration intervals, incorrect procedures or faulty calibration equipment. Over time, poorly designed or ageing sensors may drift or fail entirely. Contamination presents further risk. Dust, soot, oil and moisture can obstruct gas paths or degrade optical components. Exposure to aggressive chemicals may permanently reduce sensor sensitivity. Cross-sensitivity to non-target gases can also produce misleading data, particularly in complex combustion environments. Environmental conditions can exacerbate these issues. Temperature and humidity extremes may affect analyser stability, while physical shock or vibration can compromise system integrity. In boiler houses and industrial plant rooms, strong electromagnetic fields and power supply disturbances may also interfere with electronics if instruments are not adequately protected. Incorrect installation or operation remains an additional cause of performance issues. Customer-led development Clements says that Signal Group manufactures a range of sample handling and calibration equipment, originally developed in response to customer requirements. These ancillary systems are designed to support measurement integrity and address common sources of error identified in the field. Clements emphasises that product development is shaped by operational experience: “With almost 50 years of experience, helping to fix poor sampling systems or replace competitors’ analysers, we know the true cost of unreliability.” Recent product developments include detachable screens, remote communications capability and portable volatile organic compound (VOC) analysers. Detachable screens were introduced to address installation challenges in difficult environments. Gas analysers are often located in areas with restricted access such as ATEX enclosures, raised gantries around stacks, vehicle exhaust test cells or combustion test rigs. The ability to operate an analyser remotely, at distances of up to 50 metres, can improve both safety and practicality. Remote communications functionality has also been incorporated into newer instruments. Each analyser has its own IP address and can interface via 3G, 4G, GPRS, Bluetooth, Wi-Fi or satellite communications. This enables remote monitoring of readings outside normal operating hours, supporting maintenance planning and operational oversight. Portable gas analysers provide further resilience. While commonly used for discontinuous measurements and multi-site applications, portable flame ionisation detectors (FIDs) can also serve as temporary replacements when fixed VOC monitoring systems are offline. Signal has recently introduced a portable version of its fixed VOC analysers, the S4 SOLAR XPLORE, a heated FID instrument offering many of the capabilities associated with permanent installations. Reliability as a risk-management priority In combustion applications and broader process environments, the cost of unreliable gas measurement can be substantial. From compliance exposure to inefficient operation and unexpected shutdowns, inaccurate data presents a measurable operational risk. “The cost of unreliable gas measurement can be incredibly high, representing an unacceptable risk for most businesses. For that reason, we invest heavily in developing analysers and ancillary equipment that enhance Signal’s reputation as a reliable partner.” For further information please visit: www.signal-group.com In boiler houses, burner systems and combustion processes, reliable gas analysis underpins efficiency, emissions compliance and safe operation. When analysers fail or drift out of specification, the consequences can range from reduced performance to costly shutdowns. PWE looks at the common causes of gas analyser unreliability and the operational risks associated with poor measurement. Counting the cost of unreliable gas analysers
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