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On-site Survey Analysis:
Our site survey analysis program includes an analysis of all AMETEK Process Instruments analyzers at your location in addition to an assessment of potential improvements to the analyzers or application of the analyzer on your process.
As an example, AMETEK Process Instruments Technical Service/Applications group can demonstrate the fuel savings and emissions reduction gained by measuring oxygen and combustibles by performing a site survey analysis using a portable analyzer. Our service personnel along with your operational assistance will perform air-to-fuel ratio step testing to determine the safest, lowest excess O2 set point. Combustion efficiency gain and NOx emissions reduction will be measured and recorded. A report will detail opportunities to increase your combustion efficiency and maximize fuel savings. In most cases a pay back period of less than two months can be demonstrated for the combustibles option. At the same time, we can evaluate the existing condition of your Thermox analyzers and provide maintenance, retrofit and/or new analyzer purchase suggestions.
Previous surveys conducted at major refineries in the US have pinpointed fuel savings up to $1Million per year plant-wide at a refinery fuel gas cost of $2.5/Mscf (M=1000). The equated price of refinery fuel gas and natual gas increased 2 to 3X since the surveys were performed. The report provides operation cost information and ROA periods for analyzer retrofit, purchase, combustibles and auto-calibration options.
A sample copy of a site survey report is available below in pdf format. The report summarizes the testing results in terms of fuel savings and NOx emissions reduction. A sample of small, medium and large heaters were tested using a portable analyzer to demonstrate the optimum control point and ROA for the proposed retrofit or replacement with IQ or Series 2000-based analyzers and options. The spreadsheet below outlines "what if" scenarios based upon DCS data and conservative optimization estimates for the balance of process heaters in the refinery.
 ACME Refinery (Process Heater Efficiency Testing Results).pdf
ACME Spreadsheet.pdf
Contact AMETEK Process Instruments Service or Sales to arrange a site survey analysis of your facility today by calling 412.828.9040.
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