Abstract
M.Phil. (Engineering Management)
Oxygen concentration measurements are used in different applications including energy conservation, pollution reduction and process quality control. The use of these applications is through many different technologies of instruments. Zirconia-based Oxygen Analyzers however, are commonly used for combustion control, burner optimization and to increase the efficiency of boilers and industrial heaters in order to achieve fuel conservation. In this instance, I will be exploring the ZR22G of Yokogawa. The ZR22G is like any other instrument in that; there is a possibility of failure during operation. Therefore using of logistics engineering elements and reliability techniques ensures that the ZR22G is supported effectively thought out its life cycle.
The purpose of this dissertation is to determine the possible causes of oxygen concentration fluctuating greater or lower by 0.5% on ZR22G compared to a portable oxygen meter, and identify the risks associated with the unit reading higher or lower than the true value and determine the logistic footprint (life cycle support system) of the zirconia oxygen analyzer.
The mini dissention uses a qualitative and quantitative approach, a structured questionnaire as well as an analysis of literature.
The FMECA and FTA models established that a lower reading than true value is caused by indirect and direct human engagement with the unit and the use of combustible materials during the process. The FMECA and FTA models established a higher reading than true value is also a result of direct or indirect human engagement with the unit, Fly ash and the use of combustible materials during the process.
It was established that the risk associated with the failure mode of the unit causes hazards and creates a costly environments. In addition, it was established that incorrect reading of the unit output can cause the process operator to actor incorrectly. Preventive maintenance and corrective maintenance are maintenance activities that are required to support the unit thought-out its life cycle .Furthermore, the use of the convection tube method decreases the effect of fly ash by prolonging the blockage of the ZR22G zirconia sensor.
The benefit of this mini dissention is to provide users of the ZR22G with a guide which will assist in finding fault in the ZR22G moreover make them aware of risk associated with the unit not performing optimally.