Our Partnership with Pass Ltd

Background

Founded in early 2001 and based in Stockton-On-Tees, PASS Ltd is a leading supplier of test equipment, training, and calibration. Built on delivering an exceptional customer experience, they have grown to offer one of the most comprehensive catalogues of test and measurement, thermal imaging, and industrial safety products, as well as a broad calibration scope. In 2014, their calibration and repair laboratories gained UKAS accreditation. PASS Ltd pride themselves on offering a fast, affordable service; therefore, they have developed an online asset management portal for larger businesses to provide 24/7 access to asset details and service tracking. Additionally, as an accredited training provider specialising in low and high voltage courses, PASS Ltd offers an ever-expanding range of classes including City & Guilds and MCA accredited programmes.

Views on HVAC

PASS Ltd understand that confined spaces can be extremely dangerous and this is what makes these areas such a cause for global concern. They acknowledge that not all confined spaces are fully enclosed but point out that these locations may still pose a significant risk due to hazardous substances or conditions within or nearby the space, for example, a lack of oxygen. It is therefore critical to provide education and training on dangerous gases and environments to those working in the HVAC industry.

Working with Crowcon

PASS Ltd have been a long-term partner of Crowcon. For over seven years our partnership has enabled new areas of growth within the HVAC and portables industries. PASS Ltd attest that “our partnership has allowed us to supply a range of gas detection products and services that are reliable and diverse, improving the safety of our customers working within the Gas, HVAC, and Plumbing sectors. Crowcon’s quality and values align well with PASS’ ethos; they are the perfect partner to support our mission of raising end-users’ and businesses’ awareness of gas exposure.”

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Where do Flue Gas Analysers Fit into the UK Government’s Decarbonisation Plans?

When the UK government announced, in March 2021, that £1 billion of already-allocated funds would be redirected to projects designed to reduce greenhouse gases, the energy sector sat up and listened. And with good reason – as it turned out, £171 million will be allocated to an industrial decarbonisation plan that focuses on hydrogen gas generation and carbon capture and storage technologies.

However, the news extended beyond green energy production and is relevant to domestic and industrial HVAC applications. In a gesture that reflects the role HVAC engineers and manufacturers can play in sustainability, more than £900 million will be spent upgrading public buildings, like schools and hospitals, with greener fittings such as heat pumps, solar panels and insulation, which will reduce carbon dioxide (CO2) emissions.

But where does this leave the individual households and business units that many HVAC staff visit daily? That is a question that several commentators have asked, and it seems that – for now at least – the main drive to reduce the environmental impact of privately-owned heating and plumbing systems will continue to come from the manufacturers, engineers and installers working in the HVAC sector.

And that’s quite a responsibility. According to the Office for National Statistics, in 2020, there were approximately 27.8 million households in the UK; government statistics from 2019 indicate that around 15% of greenhouse gas emissions in the UK (specifically of carbon dioxide, along with methane, F gases and nitrous oxide) came from those residential settings. That’s a lot of excess CO2 to clean up.

So, what can HVAC people do to help decarbonisation?

If they have decent equipment, heating engineers and plumbers can help to reduce that figure by 15%. For example, they are well placed to measure CO2 and other greenhouse gases: while most flue gas analysers will measure CO2, some can also measure NO/NOx (for example, the Sprint Pro 5 and Sprint Pro 6) well.

A flue gas analyser that gives a wide range of easy-to-read and interprets measurements allows engineers to see when appliances are not working correctly and whether an upgrade (for example, to a government-subsidised heat pump) might be in order.

This is a pressing need: many households hang onto appliances for as long as possible, even though older appliances tend to be much less environmentally friendly than their modern counterparts. This is bad enough for the environment, but using a malfunctioning older appliance is the worst of all possible outcomes.

A good flue gas analyser will provide the readings required to convince many customers to decarbonise their homes or businesses more effectively. It will also allow the engineer to fix many problems in more modern and efficient appliances, bringing them back to their original operating standards and protecting the planet once more.

Helping to reach net zero

In late 2021, the UK government set out its plan to reach net-zero emissions by 2050 and every heating engineer in the country has a part to play in that project. While checking flue gases may be an everyday event for many HVAC engineers, the fact remains that household and business emissions account for a substantial proportion of CO2 output and emissions of other dangerous gases. While persuading a single household to operate with lower carbon emissions may not seem like a big deal, the impact can be very substantial when this is scaled up across the country.

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Annual Calibration for Optimal Flue Gas Analyzer Performance

For many heating engineers, the flue gas analyser/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 analyser 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 analyser 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 analyser is safety equipment and its accuracy may be – quite literally – a matter of life or death. The sensors inside flue gas analysers 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 analyser 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 analyser failed to detect an issue. If that analyser 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 analyser 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 analyser and the instruments software will be adjusted to make sure it takes into account any drop off in sensor response and to ensure the analyser responds 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 analyser, so you should never postpone or overlook your annual calibration: in fact, you must not use a flue gas analyser 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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Flue Gas Analyzer Calibration Guide

Ensuring your flue gas analyser (FGA) is regularly maintained goes without saying, however the hows and whys take a little more digging into. This article breaks down the calibration process and highlights handy tips and tricks for maintenance and best practice.

The Act of Calibration

Calibrating an FGA involves checking the sensors to ensure accurate measurement of a known concentration of certified calibration gas. To do this, the reading needs to be adjusted to match the gas concentration through an initial sensor calibration of the new or existing unit.

Next up is a calibration drift – this is done using existing instruments to bring the reading back after the drift occurs. Measuring the amount of drift in the gauge is a chance to see how far into inaccurate territory it has moved, and rule out measurement errors moving forward.

Regularity is key

Sensors degrade over time with each sensor having a different life span of optimum operation, whether it is an electrochemical, catalytic bead and infra-red sensors. Regular calibration raises the gain levels and brings the sensor back in line to avoid dangerous incorrect readings.

Once the sensor reaches a certain point it cannot be brought back into the correct position and this is the time when a new sensor needs to be installed.

Explaining the calibration procedure

The first step of the process is to set the device to calibration mode. This feeds a test gas of a known concentration onto the sensors to see how they respond. The gain levels are adjusted within the sensor to match the readings to the concentration fed in whilst mitigating drop off.

The new settings are locked into the device’s firmware and a calibration report is produced, creating a PASS or FAIL result.

Best Practice Tips and Tricks

Here are some best practice recommendations to help you maintain your FGA.

Clear out the water trap regularly – moisture is a by-product of combustion and can get sucked into the FGA when a test is undertaken. Water damage is the primary cause of damage in flue gas analysers, so it is imperative to check, empty and replace the unit’s inbuilt water traps and filters to protect from this.
Purge the device in clean air before powering down – noxious gases are drawn from the flue and passed over the sensors to gain a reading. After a test is completed and the system closes down some of that gas remains trapped inside. This can cause corrosion damage and shorten the life of the unit, so purging in clean air prior to shut down is a must.
Take inside to protect from cold weather conditions – to lessen the chances of condensation build up and water damage within your FGA make sure to remove the unit from your van overnight. This also reduces the risk of theft.
Use approved chargers with outputs tailored for target device – non approved chargers cause damage to the battery and lessen charge retention, or even impairment to the battery and IC chips of the device itself.
Check the devices’ probes and connector pipes – any splits or cracks in the rubber house will cause incorrect readings. Performing periodic checks on your hoses to ensure they are in good operating condition is a useful habit.

All-Inclusive Service Options

You have multiple options when sending your device off for it’s annual service and calibration:

Send it direct to us

Crowcon’s innovative Autocal jig system manages the end to end calibration process for Sprint Pro FGA’s. An out-of-calibration unit leads to errors in the combustion reports produced and could disrupt your day to day.

Autocal servicing is easy. Simply bring your FGA to one of the DPD drop off locations, your unit will be inspected, tested and calibrated within two days and returned to you using DPD’s express return trackable option.

For more information please check out https://shop.crowcon.com/.

Send it to your local store

Drop your device in to your local trade counter or specialist servicing centre at a time convenient to you and they will work with us to facilitate the annual calibration.
They will contact you to come and collect your device once the calibration is completed.

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Why HVAC professionals are at risk from Carbon Monoxide – and how to manage it

Carbon Monoxide (CO) is an odourless, colourless and tasteless gas that is also highly toxic and potentially flammable (at higher levels: 10.9% Volume or 109,000ppm). It is produced by the incomplete combustion of fossil fuels such as wood, oil, coal, paraffin, LPG, petrol and natural gas. Many HVAC systems and units burn fossil fuels, so it’s not hard to see why HVAC professionals may be exposed to CO in their work. Perhaps you have, in the past, felt dizzy or nauseous, or had a headache during or after a job? In this blog post, we’ll look at CO and its effects, and consider how the risks can be managed.

How is CO generated?

As we have seen, CO is produced by incomplete combustion of fossil fuels. This generally happens where there is a general lack of maintenance, insufficient air – or the air is of insufficient quality – to allow complete combustion.

For example, the efficient combustion of natural gas generates carbon dioxide and water vapour. But if there is inadequate air where that combustion takes place, or if the air used for combustion becomes vitiated, combustion fails and produces soot and CO. If there is water vapour in the atmosphere, this can reduce the oxygen level still further and speed up CO production.

What are the dangers of CO?

Normally, the human body uses haemoglobin to transport oxygen via the bloodstream. However, it is easier for the haemoglobin to absorb and circulate CO than oxygen. Consequently, when there is CO around, danger arises because the body’s haemoglobin ‘prefers’ CO over oxygen. When the haemoglobin absorbs CO in this way, it becomes saturated with CO, which is promptly and efficiently transported to all parts of the body in the form of carboxyhaemoglobin.

This can cause a range of physical problems, depending on how much CO is in the air. For example:

200 parts per million (ppm) can cause headache in 2–3 hours.
400 ppm can cause headache and nausea in 1–2 hours, life threatening within 3 hours.
800 ppm can cause seizures, severe headaches and vomiting in under an hour, unconsciousness within 2 hours.
1,500 ppm can cause dizziness, nausea, and unconsciousness in under 20 minutes; death within 1 hour.
6,400 ppm can cause unconsciousness after two to three breaths; death within 15 minutes.

Why are HVAC workers at risk?

Some of the most common events in HVAC settings may lead to CO exposure, for example:

Working in confined spaces, such as basements or lofts.
Working on heating appliances that are malfunctioning, in a poor state of repair, and/or have broken or worn seals; blocked, cracked or collapsed flues and chimneys; allowing products of combustion to enter the working area.
Working on open-flued appliances, especially if the flue is spilling, ventilation is poor and/or the chimney is blocked.
Working on flue-less gas fires and/or cookers, especially where the room volume is of inadequate size and/or the ventilation is otherwise poor.

How much is too much?

The Health and Safety Executive (HSE) publishes a list of workplace exposure limits for many toxic substances, including CO. You can download the latest version free of charge from their website at www.hse.gov.uk/pubns/books/eh40.htm but at time of writing (November 2021) the limits for CO are:

Workplace Exposure Limit

Gas	Formula	CAS Number	Long Term Exposure Limit (8-hr TWA Reference Period)	Short Term Exposure Limit (15-min Reference period)
Carbon monoxide	CO	630-08-0	20ppm (parts per million)	100ppm (parts per million)

How can I stay safe and prove compliance?

The best way to protect yourself from the hazards of CO is be wearing a high quality, portable CO gas detector. Crowcon’s Clip for CO is a lightweight 93g personal gas detector that sounds at 90db alarm whenever the wearing is being exposed to 30 and 100 ppm CO. The Clip CO is a disposable portable gas detector that has a 2-year lifespan or a maximum of 2900 alarm minutes; whichever is sooner.

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