Gas monitoring in industrial environments is critical because many toxic, corrosive, asphyxiant, and combustible gases are present, posing significant health and safety risks to workers. Failure to monitor these gases can lead to severe consequences including illness, injury, and even death. Ensuring clean air and worker safety is paramount, and gas detection systems provide crucial protection of human life.
Commonly monitored gases include toxic gases like anhydrous ammonia used in refrigeration, hydrogen sulfide found in sewage systems, and carbon monoxide from engine exhaust. Asphyxiant gases, which reduce oxygen levels, are also monitored, as are various combustible gases which can reach their lower explosive limit.
Fixed gas detection systems consist of a sensor and a transmitter. The sensor, installed near a potential hazard, detects gas presence and concentration. The transmitter interprets the sensor output and sends signals to the control system. Upon detection of hazardous gas levels, the system activates alarms, sirens, and other automated safety measures linked to the site’s Distributed Control System (DCS). Sensors are consumable items requiring periodic calibration or replacement, while transmitters are typically fixed and require no preventive maintenance.
Several types of sensors are used for gas detection:
The LEL is the lowest concentration of a combustible gas in air that can produce a flame in the presence of an ignition source. It’s expressed as a percentage of the gas volume in air and varies between gases. It’s vital for safety because exceeding this level greatly increases the risk of explosions. Gas detectors often display readings as a percentage of the LEL (100% LEL = the gas is at its LEL concentration).
A K-factor is a corrective mathematical factor applied in the transmitter for IR and catalytic bead sensors. It’s necessary when the calibration gas used is different from the target gas. Since these sensors interact with multiple combustible gases, the K factor adjusts the sensor readings, ensuring accurate measurements for the specific target gas. If multiple gases are present, the highest K factor should be programmed into the sensor.
Proper sensor placement is critical to ensure reliable detection. Lighter-than-air gases (like ammonia) require sensors to be placed higher, while heavier-than-air gases accumulate near the ground and require lower placement. Oxygen sensors are placed in the breathing zone. Sensors should be located where the highest concentration of the target gas is likely to occur, avoiding diluted samples. Remote sensors can be mounted up to 100 feet from the transmitter. A sample draw system can be used for difficult-to-access locations, pulling gas samples to a sensor located in a safer area.
Calibration is critical to ensure sensor accuracy by comparing the sensor to a known gas standard. It’s recommended upon installation, after high-level readings, or extended exposure to the target gas. Hazardous area classifications are used to ensure electrical equipment is used safely in areas with potentially explosive atmospheres. These classifications are determined by the combustible source and the likelihood of its presence, with equipment having specific engineering controls to prevent ignition. Understanding these classifications is crucial for selecting appropriate equipment, and for worker safety.
