The use of gasses in various industrial processes is inevitable. While these gasses can be vital in the production process, they also pose significant hazards to employees and the environment. The risks range from asphyxiation, explosion, suffocation, and burns, just to mention a few. Consequently, the implementation of a reliable gas detection system in industrial settings is imperative to ensure the safety of workers and the environment. Gas detection systems use gas sensors to identify the presence of toxic gasses such as CO2, CO, NOx, H2S, Methane, and others in industrial facilities.

Here is an overview of the importance of gas detection, the dangers of industrial gasses, the most common industries and processes requiring gas detection, and the consequences of inadequate gas detection systems. We will also explore the evolution of gas detection technology, the different types of gas detection sensors and their applications, relevant standards and regulations, benefits of using GasFinder technology, integration with other safety systems, maintenance and testing requirements, and employee training on gas detection safety measures.

Benefits of Gas Detection Systems

Gas detection systems offer several benefits in industrial settings. They help detect the concentration of gasses present in the atmosphere to avoid hazardous consequences like fire breakouts and explosions. They also help maintain proper oxygen levels for workers, comply with emission regulations and norms, and avoid unwanted leakage and consequences like poisoning or explosions.

Industries Where Gas Detection Systems are Essential

There is a broad range of industries that use gasses in their production processes. Gas detection and monitoring systems are essential in various industries, from small boiler rooms to large-scale petrochemical industry installations. Below are some of the most industry verticals where gas monitoring and detection systems are a must:

  • Semiconductor Manufacturing Industries
  • Oil and Gas Industry
  • Chemical Industry
  • Mining Industry
  • Food and Beverage Industry

In these industries, gas detection systems allow different industrial segments to supervise and control the use of toxic gasses and asphyxiants in their facilities. Gas monitoring solutions can ensure an oxygen-rich environment for workers and equipment, preventing accidents and ensuring safety.

Dangers of Industrial Gases

Many industrial gasses, such as methane, oxygen, nitrogen, hydrogen, and carbon dioxide, are invisible, odorless, and tasteless. Failure to detect and remove these gasses from the air can cause harm to employees, animals, and plant life. The gravity of the situation is even more severe when these gasses mix with the air and ignite, leading to explosions.

In some cases, the gasses present in the industrial environment are not necessarily toxic but can pose a suffocation hazard. For instance, in places where nitrogen is present in high levels, it can displace air, leading to a situation called anoxia. In this scenario, employees can be smothered because there is not enough air to breathe.

Consequences of Not Having Proper Gas Detection

Inadequate or absence of a gas detection system in industrial settings can have disastrous consequences. The risks include injury, loss of life, and liability. At the very minimum, industries must operate in accordance with relevant regulations and standards that require effective gas detection systems. Any failure to meet these standards could result in hefty fines, legal action, damage to facility reputation and branding, and lowered employee morale.

Evolution of Gas Detection Technology

Over the years, advancements in gas detection technology have resulted in more reliable and efficient systems. One significant milestone was the development of infrared sensors that can detect gasses even at low concentrations. Moreover, it is now easier to integrate gas detection systems with other security systems, allowing for more proactive monitoring of gas levels.

Types of Gas Detection Sensors and Their Applications

There are four main types of gas detection sensors that are commonly in use in modern industrial settings:

1. Catalytic Bead Sensors

Catalytic bead sensors are mainly used to detect combustible gasses. The core of the technology consists of two electrically heated wire coils coated with a catalyst such as platinum or palladium. When a combustible gas comes into contact with the bead, it reacts, producing heat. The change in temperature is detected by the sensor, alerting employees to the presence of potentially dangerous combustible gas levels.

2. Electrochemical Sensors

Electrochemical sensors are used to gauge the concentration of toxic gases such as hydrogen sulfide, chlorine, and carbon monoxide. The technology operates by measuring the degree to which a target gas oxidizes the anode and reduces the cathode. The outcome is a change in electrical conductivity, which is used to determine the concentration levels of the gas.

3. Infrared Sensors

Infrared sensors are particularly useful for identifying the gasses that are difficult to detect, including carbon dioxide, methane, and certain refrigerants. The infrared technology works by measuring the amount of infrared absorption in a gas sample. The sensors differentiate the gas because each gas has a unique absorption spectrum.

4. Ultrasonic Gas Detection Sensors

Ultrasonic sensors pick up the distinct sound waves produced by gas leakage. The sensors are highly reliable, require little maintenance, and are relatively simple in design. Furthermore, ultrasonic sensors are non-intrusive, meaning there is no need to penetrate the walls or pipelines during installation. 

Relevant Standards and Regulations

The most common regulatory standards regarding gas detection in industrial settings are OSHA and EPA standards. The Occupational Safety and Health Administration (OSHA), requires employers to provide their employees with the right equipment and tools to spot and handle hazardous atmospheres. Moreover, OSHA mandates that employers follow standards such as the alarm thresholds that trigger worker exposure and evacuation requirements.

The Environmental Protection Agency (EPA) sets the minimum emission thresholds for contaminant release into the environment. Industries must adhere to these standards, and failure to comply will result in penalties.

Benefits of Using GasFinder Technology

GasFinder technology is ideally suited for numerous safety, environmental and process applications. It is a reliable and robust solution for detecting gas concentrations in industrial settings. The GasFinder system features internal calibration and requires little maintenance, making it an ideal solution for critical applications. The system can be configured as a multi-channel or single channel and with field-mounted transmitters used for both “Open area” and “stack / duct” monitoring.

Integration with Other Safety Systems

It is essential to integrate gas detection systems with other safety systems in industrial settings for better monitoring. Coordinated real-time monitoring and data acquisition with other safety systems can offer enhanced situational awareness of the facility. In case of an emergency, an integrated system can ensure prompt response and minimize the possibility of harm to employees.

Maintenance and Testing Requirements

Gas detection systems require proper maintenance and calibration to ensure that they remain accurate and reliable over time. Regular maintenance ensures that gas detection systems have optimal performance levels, and calibration ensures correct levels of detection and monitoring. Instituting proper servicing programs, installation of new sensors, tune-ups and recalibration are necessary to ensure consistent operational performance.

The maintenance and testing requirements for gas detection systems are dependent on various factors such as the size of the facility, the type of gasses in use, and the location of use. All gas detection systems must be tested regularly for proper operation. In case of a malfunction, the system should be repaired immediately.

Employee Training on Gas Detection Safety Measures

It is crucial for employees to undergo proper training and education to understand the risks associated with industrial gasses and the right gas detection safety measures. All workers must be made aware of the standards, regulatory requirements, and best practices in the industry. Education and training should be ongoing to keep employees updated on advancements in technology and to refresh their knowledge on protocols.

Safety should be the priority in all industrial operations that use gasses. Proper handling and measuring of gas leakage in the production chain is necessary for its efficient operation. Whether you are using toxic, corrosive, or different types of gasses that require different gas detection technologies, selecting the appropriate gas detection system while ensuring that the system is correctly maintained and calibrated is imperative. The experience of navigating safely in the dangerous environment of industrial gasses is essential. Professionals operating in the industrial space should take safety measures and use gas detection systems to safeguard the environment, protect lives, and ensure effective and efficient operation of their industrial processes.

In conclusion, the implementation of a reliable gas detection system in industrial settings is essential to prevent injuries, loss of life, and liability while ensuring compliance with relevant regulations and standards. The four main types of gas detection sensors are catalytic bead sensors, electrochemical sensors, infrared sensors, and ultrasonic gas detection sensors. It is worth noting that no single sensor or technology is superior for all applications. The system best suited to a specific industrial process depends on the gaseous substances present, the environment, and potential hazards to employees. GasFinder technology is ideally suited for multiple safety, environmental, and process applications and is relied upon by businesses worldwide. In order to ensure the safety of employees, it is important to continually maintain, test, and refine gas detection systems and regularly train employees on the safety measures.