Gas analysis instruments are key equipment for ensuring industrial production safety and energy efficiency, and their accuracy and stability depend on regular calibration and scientific maintenance. The following will explain from three aspects: calibration process, maintenance points, and common problem handling.

1、 Calibration process

Calibration cycle and selection of standard gas

Regular calibration is recommended once every quarter, while high-precision demand scenarios (such as coking plant gas purification) require monthly calibration.

Use multi-component standard gases (such as mixtures containing CO, H ₂, CH ₄, and O ₂), with concentrations covering the actual operating range (such as CO2 5%~30%, O ₂ 0%~5%).

Standardized calibration steps

Zero point calibration: Introduce high-purity nitrogen gas (O ₂ ≤ 0.1ppm) and reset to zero after the reading stabilizes.

Range calibration: sequentially introduce low, medium, and high concentration standard gases, adjust the instrument output to the theoretical value, and the error should be ≤ ± 2% FS (full range).

Linear testing: Draw a calibration curve to ensure that R ² ≥ 0.999.

Environmental condition control

Calibration temperature is 20 ± 5 ℃, humidity is ≤ 80% RH, to avoid measurement deviation of ± 1% FS caused by temperature and humidity fluctuations.

2、 Maintenance points

Sensor maintenance

Electrochemical sensors have a lifespan of 1-2 years and require regular replacement of the electrolyte; Infrared sensors need to clean the optical window every six months to avoid oil contamination.

The laser sensor needs to be shock resistant and dust-proof, and the laser power attenuation should be checked regularly (calibration is required when it is ≤ 80% of the initial value).

Pipeline and gas path inspection

Check the sealing of the sampling pipeline every month, with a leakage rate of ≤ 0.1L/min; The filter element should be replaced every quarter to prevent particle blockage.

Electrical system maintenance

Check the output stability of the power module annually, with a fluctuation range of ≤± 5%; Grounding resistance ≤ 4 Ω to prevent electromagnetic interference.

3、 Common problem handling

reading drift

Reason: Sensor aging, pipeline contamination.

Solution: Replace the sensor or clean the pipeline, and recalibrate.

Slow response

Reason: Filter blockage, insufficient air pump pressure.

Solution: Replace the filter element and check the output pressure of the air pump (≥ 0.3MPa).

Abnormal fluctuations in data

Reason: Electromagnetic interference, sampling pump vibration.

Solution: Install a shielding layer and fix the position of the sampling pump.

Through standardized calibration and preventive maintenance, the lifespan of gas analysis instruments can be extended to over 5 years, ensuring the safe production and compliant operation of enterprises. It is recommended to establish a maintenance file to record calibration time, sensor replacement cycle, and fault symptoms, in order to quickly trace problems.