A leading international energy company was seeking to improve the reliability of its online process gas analysis within one of its large-scale refining facilities. Continuous gas sampling was critical to monitoring process conditions across several production units, enabling operators to optimise efficiency, maintain product quality, and ensure compliance with environmental and safety standards.
The existing sampling pumps were experiencing increased maintenance requirements due to the demanding operating environment, resulting in unplanned downtime and reduced analyser availability.
The Challenge
The refinery required a gas sampling solution capable of:
- Delivering a continuous, stable flow of process gas to online analysers.
- Operating reliably within a hazardous area environment.
- Preventing contamination or leakage of sampled gases.
- Minimising maintenance and extending service intervals.
- Integrating with the site's existing analyser systems without major modifications.
Given the critical role of process analysers in refinery operations, maintaining uninterrupted sample flow was essential to ensure accurate process control and maximise plant availability.
The Solution
The refinery selected the Air Dimensions R121-FP-QB2-E1Y Dia-Vac® diaphragm gas sampling pump for installation within its process analyser system.
Designed for continuous-duty operation, the pump's oil-free diaphragm technology provided clean, leak-free transfer of process gas to the analytical equipment. Its hazardous area configuration made it suitable for installation within classified refinery environments, while its robust construction enabled dependable operation under demanding process conditions.
The pump was integrated into the refinery's online gas analysis system, continuously delivering representative gas samples from process lines to gas chromatographs and other analytical instruments used for real-time monitoring.
Results
Following installation, the refinery achieved several operational improvements:
- Improved reliability of continuous gas sampling across critical process units.
- Reduced maintenance requirements compared with the previous sampling equipment.
- Increased analyser uptime, supporting uninterrupted process monitoring.
- Consistent sample delivery, contributing to improved analytical accuracy and process optimisation.
- Enhanced operational confidence through dependable performance in hazardous operating environments.
The improved reliability of the sampling system helped maintenance teams reduce planned intervention frequency while providing operations personnel with consistent analytical data for process control.
Conclusion
The Air Dimensions R121-FP-QB2-E1Y provided a dependable solution for continuous process gas sampling within a demanding refinery environment. Its oil-free, leak-free diaphragm design, combined with suitability for hazardous area applications, supported reliable analyser performance and helped improve plant efficiency, operational reliability, and process control.
By enhancing the integrity of the refinery's gas sampling system, the solution contributed to more consistent process monitoring while reducing maintenance demands and supporting safe, continuous operation.
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