Blogs listed by category: Category: Training

Annual Calibration for Optimal Flue Gas Analyzer Performance

For many heating engineers, the flue gas analyzer/combustion analyzer is vital kit; so much so, that most would have problems working without one. However, calibration and servicing generally require the engineer to send the analyzer away for a while. That’s why, when the annual calibration date comes around again, some find themselves tempted to put it off, just for a while 
 

Please ignore that temptation. It is absolutely vital to get your flue gas analyzer calibrated every year, and failing to do so could cost you your job – or worse. Prompt annual calibration is simply not negotiable, and in this blog post we’ll explore the reasons why. 

Annual certification required 

A flue gas analyzer is safety equipment and its accuracy may be – quite literally – a matter of life or death. The  sensors inside flue gas analyzers react with the gasses they detect and degrade slightly over time. Compiled over the course of a years active use, the degradation can lead to inaccuracies in the readings.  Additionally, like any equipment, things can go wrong and parts can fail; that’s why all flue gas analyzer manufacturers require an annual certificate of calibration, and the impact of not having one can be legally, financially and personally disastrous. 

Imagine, for example, that an accident has occurred and somebody or something has been harmed because your flue gas analyzer failed to detect an issue. If that analyzer was uncertified and had not been calibrated within the time period required (which would be easy to ascertain, since gas reports have the relevant times and dates printed on them), then you and/or your employer may be held criminally and civilly liable for this, having failed to exercise your duty of care to your client.  

That’s why, if your combustion analyzer is showing any signs of failure, or if your annual calibration is due, you need to book it in promptly. 

What about costs? 

Sometimes, engineers are tempted to put off calibration for fear of the costs. And yes, there may be charges involved due to damage or wear and tear: but what price do you put on safety (both the safety of the people you serve the security of your own job or business?) If cost is an issue, there may be ways to mitigate this. Manufacturers know that calibration is a recurring cost and some offer pre-pay options to make this easier to manage; some offer pre-pay options for parts as well. If you’re not sure whether this is the case for your device, it is worth talking to the manufacturer because the savings can be substantial. 

What happens during calibration? 

During its annual service and calibration, your flue gas analyzer will be checked over and any components (for example, an oxygen sensor) will be replaced as required. A known concentration of certified test gas will be passed into the analyzer and the instruments software will be adjusted to make sure it takes into account any drop off in sensor response and to ensure the analyzerresponds appropriately to all gases across the range of detection.  

Don’t wait – calibrate 

As you can see, calibration and any associated changes are vital to the functioning of your analyzer, so you should never postpone or overlook your annual calibration: in fact, you must not use a flue gas analyzer at all, once the previous calibration has expired. This applies however often (or not) you use it: the risks are the same.  

To find out more, visit our dedicated HVAC page.

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National Apprenticeship Week 

At Crowcon we have a passion for gas detection, for over 50 years we have been manufacturing high quality gas detectors that are reliable and have technical innovation. In a week that brings businesses and apprentices together to highlight the positive impact apprenticeships have on individuals, business and the wider economy, we are delighted that we offer such apprenticeships here at Crowcon.  

With over 25 employees having completed an apprenticeship and three currently going through the process, we know apprenticeships are more than just a qualification, they offer experience to become a professional in a chosen trade, helping to make an impact in the business all whilst earning a wage.  

“Apprenticeships are still undercelebrated despite of all the benefits they bring to both the individuals and the business. They perfectly blend theory and practical skills together into a learning-working experience that is like no other. Crowcon has seen many of our colleagues successfully graduate form apprenticeships with HNC, HND and even bachelor’s degrees. I would strongly encourage today’s youth to consider apprenticeship route, especially females within STEM. I have no doubt that it will unlock many career opportunities for you” – Birute Infantado, Human Resources Manager. 

In the process of building your engineering career through an apprenticeship scheme at Crowcon, you will experience a work environment day-to-day in parallel whilst gaining the benefits from experienced colleagues and mentors who can help you build your skills and take them straight into the workplace. 

An advanced apprenticeship at Crowcon takes three years to complete. We work closely with local colleges to provide apprenticeship programs with the opportunity to continue your academic studies at both Newbury College that covers engineering or Abingdon and Witney College that supports business improvement. The scheme combines 80% work and 20% learning time. 

We believe that home grown talent is the future. Although higher education has now become an expectation in the workplace, the cost of higher education is leading many to re-think the automatic study routes. Vocational career paths have become widely available, offering a multitude of opportunities and development routes. People development is at the heart of our business success and working collaboratively to release the wider potential within our business is how Crowcon will continue to go from strength to strength. 

Following completion of the three-year apprenticeship, previous apprentices have developed the scope to move into engineering roles after a few years in the Line Technician position. Not only have all our apprentices been placed in permeant jobs within Crowcon following the end of their apprenticeships, but some have even continued with higher level apprenticeship studies. Some of the previous apprentices have taken roles in Test and Verification, Quality Engineering, Manufacturing Engineering and Project Management within R&D. 

Hear what some of our current apprentices have to say: 

“One of the things I particularly enjoy about the apprenticeship is the fact you earn while you learn, with the opportunity to continue into higher education all supported and sponsored by the company, meaning no hefty student loan. Additionally, with a tailored training and development plan directly related to the job – you pick up a lot of useful/ specialist skills along the way which puts you in line for great career prospects and progression. I would recommend the apprenticeship route as it gives you the opportunity to learn within the industry, whilst putting these into practice in real world scenarios, which is just as valuable as going to university” – Alex Watson, Test and Verification Technician 

“The apprenticeship gave me an insight and understanding into LEAN practice and has given me the tools to streamline production and improve processes.  Working in small teams with other apprentices doing the same course was good as we all had different opinions and views which was also a good learning process for me” – Debbie Murphy, Team Leader.  

“I am currently undergoing Level 3 Engineering Technician course, where I am learning the basics of electronics as well as building and testing my own circuit boards. The apprenticeship is allowing me to develop my social skills as well as get hands on by combining my learning and work together” – Ethan Shurmer, Line Technician.  

“Throughout my time at Crowcon, I have completed 4 apprenticeships from level 3 to level 6. The apprenticeships have allowed me to work in real world environments giving the options to gain the essential experience needed for future careers choices and have provided me with the skills and knowledge to progress further within the engineering industry” – Vikesh Patel, Junior Project Manager.

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Why enter into an apprenticeship at Crowcon?

“Working at Crowcon provides me with all the necessary skills required to become a competent engineer within the industry.” Noah Fisher

Apprenticeships are more than just a qualification. They allow you to become a professional in your chosen trade area, earning a wage whilst making a real impact in the business.

Whilst building your engineering career through an apprenticeship scheme at Crowcon, you’ll get experience in a work environment day-to-day in parallel with also gaining the benefits from experienced colleagues and mentors who can help you build your skills and take them straight into the workplace.

Key benefits to an apprenticeship:

 

  • Learn and earn money at the same time
  • Gain a nationally recognised qualification
  • Get relevant and practical experiences
  • Have full support, guidance and training
  • Broaden your knowledge and skillset
  • Network and collaborate with colleagues
  • Future career prospects

There is great scope to earn good rates of pay working as an engineer – across a variety of specialisms as your career develops.

Hear what some of our current apprentices have to say:

“For anyone looking to start an apprenticeship I would say go for it, as it has been a great experience for me because you get to carry out practical activities on site at Crowcon and the theory side at college on a day release type format. This is vital as it gives me the knowledge behind carrying out certain activities and it all links together with my everyday work.” Ryan Jones

 

“For someone who was interested in technology and how things work in different industries, it was inevitable that engineering would be sector in which I chose to pursue a career. However, I am also a person who wouldn’t prefer to be learning in a classroom every day. Therefore, apprenticeships allow you to work in real world environments giving the options to gain the essential experience needed for future careers choices.

Working for an established company like Crowcon provided a clear training program, both in and out of the workplace that would provide me with the skills and knowledge to progress further within the engineering industry. Given the support provided by the company I have been able to push myself in the classroom to achieve the very best. This was reflected in being awarded a variety of accolades on both local and national levels during my time here at Crowcon.”  Vikesh Patel

We’re always looking at recruiting apprentices and graduate engineers to support in achieving recognised qualifications from NVQs at Level 2 to BTECs, HNC and in some disciplines, such as finance or purchasing, post graduate or professional certificates.

Home grown talent will be the differentiator of the future. The cost of higher education is making many re-think the automatic study routes. It is no longer necessary to become burdened with a large debt, via full time study, to achieve your potential in the work place. Vocational career paths are finally becoming more widely available, with a multitude of opportunities and development routes.

People Development is at the heart of our business success and working collaboratively to release the wider potential within our business is how Crowcon will continue to go from strength to strength.

Following a successful completion of the 3 year apprenticeship, you could follow a similar path to previous apprenticeships with scope to move into an engineering role after a few years in the Line Technician position. Previous apprentices have taken roles in Test & Verification, Quality Engineering, and Manufacturing Engineering.

After all, why would you take a job, when you can have a career?

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Working together for safety at sea

Crowcon Detection Instruments is working together with Solent University’s Warsash School of Maritime Science and Engineering – all in the name of teaching engineering cadets, senior Merchant Navy officers, and Superyacht crews.

Solent delivers world-renowned yacht and powerboat design degree programs, a suite of international maritime studies courses and a wide range of specialist support services for the maritime industry. It is also conducting a large number of research studies that make a real impact on industry thought leadership.

Their partnership with Crowcon makes good sense!  The marine environment is a dangerous one – and not just the more obvious hazards like high seas, storms, or rocks and coral reefs.  Confined spaces on ships, high-risk cargo, and on-ship processes all present potential gas hazards.

To keep mariners safe, gas monitoring equipment is essential.  Gas detection equipment requires specific marine environment testing and certification to ensure suitability to the extreme environments it operates in.  The European Marine Equipment Directive (MED) approval is internationally recognised. Gas detectors used by mariners onboard a vessel registered in an EU country must hold MED approval, and show the wheel mark to demonstrate compliance.

Crowcon has provided the university with demonstration T4 portable multi gas detectors.  T4 provides effective protection against the four most common gas hazards experienced in the marine industry, and is robust and tough enough to deal with the demanding marine environments.  T4 is ideally suited to help vessels comply with multiple SOLAS requirements which dictate the need for gas detection onboard vessels.

John Gouch, lecturer at  Solent University, said: “I have used Crowcon instruments in industry for many years, and know how reliable and trustworthy their gas detectors are. Since joining Warsash 18 months ago, I have been keen to ensure students understand the important part gas detection plays within the on-board safety system.”

“By using demo units of these detectors within our marine engineering courses, we can show the importance of gas detection in a marine environment to hundreds of seafarers and mariners, keeping as many people as possible aware and safe.”

Louise Early, Head of Marketing at Crowcon, said: “We’re really pleased with our partnership with Solent University.  By developing our relationship with training establishments, our safety message gets out to the people who will benefit most. We are always keen to learn from industry and this program also offers Crowcon further insight into the way in which our equipment is used.”

For more information, visit the Solent University website, or the marine section of our industries page.

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Why monitoring oxygen doesn’t protect from carbon dioxide

Carbon dioxide (CO2) is gas used or produced in many industries, if not directly in the products, in cooling and refrigeration systems. Possibly because of its association with breathing (we breathe in oxygen and breathe out CO2), the toxic nature of CO2 is not always appreciated. As a result, some believe that the level of oxygen (O2) in the air is a suitable indicator of safe CO2 levels. However, while monitoring O2 concentrations protects you from asphyxiation, it can’t be relied upon to protect against CO2 poisoning. Making a link between safe levels of CO2 and safe levels of O2 can be a fatal error.

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Pellistor sensors – all you need to know

We’ve written about pellistor sensors before, but the information still remains vital and useful.  Here’s all you need to know


Pellistor sensors (or catalytic bead sensors) have been the primary technology for detecting flammable gases since the ‘60s. Despite having discussed a number of issues relating to the detection of flammable gases and VOC, we have not yet looked at how pellistors work. To make up for this, we are including a video explanation, which we hope you will download and use as part of any training you are conducting:

A pellistor is based on a Wheatstone bridge circuit, and includes two “beads”, both of which encase platinum coils.  One of the beads (the ‘active’ bead) is treated with a catalyst, which lowers the temperature at which the gas around it ignites. This bead becomes hot from the combustion, resulting in a temperature difference between this active and the other ‘reference’ bead.  This causes a difference in resistance, which is measured; the amount of gas present is directly proportional to it, so gas concentration as a percentage of its lower explosive limit (%LEL*) can be accurately determined.

The hot bead and electrical circuitry are contained in flameproof sensor housing, behind the sintered metal flame arrestor (or sinter) through which the gas passes. Confined within this sensor housing, which maintains an internal temperature of 500°C, controlled combustion can occur, isolated from the outside environment. In high gas concentrations, the combustion process can be incomplete, resulting in a layer of soot on the active bead. This will partially or completely impair performance. Care needs to be taken in environments where gas levels over 70% LEL may be encountered.

For more information about sensor technology for flammable gases, read our comparison article on pellistors vs Infrared sensor technology: Are silicone implants degrading your gas detection?.

*Lower Explosive Limit – Learn more

 Click in the top right hand corner of the video to access a downloadable file.

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‘World of Work’ 2016

The first week of July 2016 was work experience week for many students across Oxfordshire and also coincided with Science week. We took the opportunity to show students what opportunities are available to them if they study Science, Technology, Engineering and Mathematics (STEM) subjects at school.

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Deadly Sin No.5 – introducing other hazards

Introducing other hazards is the fifth in Crowcon’s series of Deadly Sins of Gas Detection. Most working environments where gas detection is required are already hazardous enough. The irony of using a gas detector that ends up being the cause of non-gas-related accident would not be an amusing one. Improvements in a variety of gas detection technologies mean that now this can often be avoided. Continue reading “Deadly Sin No.5 – introducing other hazards”

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Crowcon Apprentice wins Student of the Year 2016

Last night, at an awards ceremony hosted by Abingdon and Witney College to celebrate student success, one of our second year Engineering Apprentices, Vikesh Patel, won not just ‘2016 Apprentice of the Year’ but, out of around 14000 students across 2 campuses, won ‘2016 Student of the Year’ too. This makes him the first ever apprentice to win such an accolade. Continue reading “Crowcon Apprentice wins Student of the Year 2016”

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Deadly sin no.3- using the wrong equipment

 “Using the wrong equipment” is the third of Crowcon’s Deadly Sins of Gas Detection. The best of gas detection intentions can be undermined by use of the detection equipment not up to the job. There are many ways in which the accuracy and safety of gas detection equipment can be inadvertently compromised but there are some errors which can be easily avoided. To illustrate the point, here are some examples:

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