OXYFIRE INSTALLATION – COMBUSTION OPTIMIZATION


OXYFIRE INSTALLATION

Combustion Optimization


REQUIREMENTS:

OxyFire is a true in-situ sensor for improving quality, reducing scrap, saving fuel, and minimizing unwanted air pollution emissions in your furnace. The active part of the sensor is at the very tip and must be located in the gas stream of the process. The sensor is installed directly in the combustion zone, close to the combustion source. It offers a direct, continuous measurement without extractive sampling or cooling. The response time to changes in the process is less than 1 second. Stability is less than 1% deviation in signal output over the life of the sensor. The accuracy of the sensor output does not exceed ±2% of the measured variable (Example: process variable = 2%, accuracy is ±.04%).

The sensor is standard with an internal type "B" thermocouple. It offers a process temperature measurement in addition to oxygen content. The outputs from the sensor are two millivolt signals. Electrical power is not connected to the sensor since there is no heater requirement. The sensor is intrinsically safe. Calibration gases and maintenance man-hours are not needed because the sensor never requires calibration. Sensor verification and diagnostics are available thru the instrumentation, but are not a requirement.

The type of furnace and your particular process will determine the actual length and sheath material of the sensor. Standard lengths range from 6" to 42". Silicon carbide, alumina, and hi-temp alloy are the standard sheath materials.


GENERAL REQUIREMENTS FOR SENSOR INSTALLATION

  • The sensor must be installed where the process temperature is between 1200°F and 3000°F (650°C - 1600°C).
  • The atmosphere should be moving and not stagnant.
  • Ambient temperature at terminal head should not exceed 300°F.
  • The sensor should be protected from direct flame contact and should be located in an area where combustion is complete.
  • Clean, dry reference air - 50cc/min to 150cc/min at a pressure of 2psi maximum.


GENERAL MOUNTING INSTRUCTIONS:

  • May be mounted horizontally or vertically depending on type of furnace and particular process.
  • Recommended hole thru the refractory is 3" diameter (perpendicular and at right angles to exterior surface).
  • A 1˝" NPT threaded coupling is attached to exterior surface of a furnace with a metal shell. This connection must be airtight.
  • In refractory exterior furnaces, a 3" diameter hole should be used. Use ceramic fiber around the sensor to seal air leaks.
  • An 18 gauge stranded copper wire, 4 conductor, twisted - shielded pair, teflon insulation cable should be used to connect sensor outputs to instrumentation. Belden #89418 cable or equal.
  • Metal ¼" tubing is used to connect sensor reference air.


INSTALLATION IN HOT PROCESS: "CAUTION - THERMAL SHOCK

  • Use a marker to mark 1" increments along the sensor length. Insert the sensor slowly at a rate not faster than 1" every 5 minutes.
  • Keep the sensor supported during installation.
  • If a pipe coupling was used for mounting, apply teflon thread tape to sensor threads for sealing. Hand tighten sensor, and then add a quarter turn with a wrench. Over-tightening may cause sensor breakage.
  • furnace wall section sensor point
  • oxyfire sensor
OXYFIRE INSTALLATION OXYFIRE INSTALLATION 2