Detecting toxic and flammable gases is crucial for maintaining safety, regardless of the industry type, as exposure to them can lead to severe incidents, including explosions or poisoning. To this end, hazardous gas detection systems aim to ensure a high degree of protection, designed to provide early alerts and minimize risks, safeguarding both personnel and facilities, whether in the pharmaceutical industry, petrochemical, oil & gas, food industry, HVAC installations, or even closed parking areas.
Some industries are constantly exposed to risks due to the nature of their activities. The faster hazardous gases are detected, the higher the chances of avoiding a disaster, thus limiting or eliminating material damage or loss of human life from the outset.
Pharmaceutical/Medical Industry
The pharmaceutical industry is one of the most dynamically developing sectors in modern economies. The rules governing this industry, such as production, use, and packaging principles imposed by the WHO (World Health Organization) and the European Union, are becoming increasingly challenging, especially in the field of sterile products.
Many workers in the pharma industry face workplace hazards when handling chemicals, biological agents, and medications. They are exposed to substances such as harmless and harmful particles, pressurized liquid chemicals, liquid aerosols, and powders.
To ensure products have the highest quality and cleanliness, personnel must work in enclosed spaces called clean rooms, under special conditions—rooms where particle density in suspension is controlled, built and used to minimize the entry, formation, and retention of particles; parameters such as temperature, humidity, and pressure are continuously controlled.
Food and Beverage Industry
Food and beverage producers use various gases in processing and storing food and waste. The most common gas is CO2. Carbon dioxide is one of the gases present in food processing; moreover, it is colorless, odorless, and tasteless, making it very dangerous.
When CO2 levels rise, it is difficult to detect, and it can easily replace oxygen. High concentrations of CO2 cause poisoning and suffocation. In the food and beverage industry, many accidents and deaths are due to carbon dioxide emissions. To prevent unwanted events, gas detectors with IR technology allow the detection of carbon dioxide at various intervals.
Petrochemical Industry
Petrochemicals are the general name given to industrial methods used to produce chemicals from petroleum. This industry has become an indispensable point in today's economy, through the production of fertilizers and plastics.
Oil and natural gas are the first links in the petrochemical production chain. From these products, certain main chemicals are derived, which are the source of raw materials: alkenes (ethylene, propane, and butadiene), aromatics (benzene, toluene, and xylene), and methanol—subsequently transformed into a series of intermediate chemicals. Thus, the petrochemical industry is a sector where very strict safety measures are taken.
Explosion hazards are real, which is why this industry is regulated by numerous safety standards. Therefore, detectors for flammable and toxic gases are an essential element for security in such environments.
Oil and Gas Industry
Due to the large number of toxic and flammable gases generated in fossil fuel extraction processes, the oil and natural gas industry is extremely hazardous. Most accidents are due to gas leaks and explosions. Therefore, the industry needs high-level security systems to protect the workplace, people, and the environment.
The most important part of this safety chain is gas detection systems. Here, the most common sources of hazards include: hydrogen sulfide, methane, ammonia, propane, hydrogen, carbon dioxide, sulfur dioxide, volatile organic compounds, or oxygen deficiency/excess.
Additionally, liquefaction processes are a major source of potential accidents. Refrigerants such as ethane, ethylene, propane, propylene, and butane are necessary for liquefaction, and their presence can increase the risk of accidents, which is why gas detection systems are required.
Gas Distribution Industry
The transportation of natural gas requires a complex, safe, and reliable piping system. There are three main types of natural gas pipelines that vary in size and internal pressure: gathering systems, transmission systems, and distribution systems. Gathering pipelines collect raw natural gas from production wells; transmission pipelines transport it to processing facilities or storage; and the distribution system is the final part of the transportation system and allows natural gas distribution to end-users.
A malfunction in a natural gas pipeline can have consequences that represent a significant threat to people or the environment. Natural gas companies must assess negative risks, and gas detection is the number one priority for system security. Any leak or accumulation of gas can have catastrophic consequences, which is why reliable detection solutions are required.
HVAC Systems
Cooling is a process that uses a heat pump and a working agent to lower the temperature of a product, process, or space. With the banning of CFC refrigerants (Chlorofluorocarbons), HCFCs, HFCs, and PFCs began to be used in applications, but new regulations have been created to limit the effects of these gases on global warming and to rapidly detect gas leaks in cooling systems.
Additionally, cooling installations may contain other gases such as ammonia and CO2, which can cause health issues. Most people are familiar with freon as a refrigerant used for refrigeration equipment and air conditioning units at home and in industry. However, few are aware of the effect of freon on humans and the environment. In terms of toxic properties, freon is similar to other inert gases, but prolonged inhalation of these compounds has a negative effect on the body. Therefore, gas detection systems are essential where such gases are used to protect people and the environment.
Parking
At startup, vehicles emit CO and NO2, gases that can accumulate in parking areas and enclosed spaces. For health and safety reasons, CO and NO2 levels should be constantly monitored. If ventilation in these areas is insufficient, CO and NO2 can reach high concentration levels and cause health issues.
Detecting toxic gases in underground parking garages leads to safety measures for people and the environment, as well as energy cost savings. We must remember that ventilation systems use a significant amount of electrical energy if operating continuously. Therefore, an economical solution would be to activate the ventilation system only if there is an accumulation of gases above the limit. A gas detection system does not consume a significant amount of electrical energy, and fans turn on only when necessary.
Maritime Industry
It is a field exposed to many risks. Over time, there have been accidents caused by hydrocarbon leaks from oil tankers. Also, leaks from pump rooms and other machinery parts increase the risk of explosion, while leaks in empty spaces can pose a danger to the crew. Here, the role of detectors is to determine the presence of these gases.
Monitoring vapors and gases from storage tanks is an important process, maintaining safety on board. Tanks transporting cargo with a flash point below 60 °C must be equipped with a continuous monitoring system for hydrocarbon gas concentration in pump rooms. Sampling points or detector heads must be placed in suitable locations so that potentially dangerous leaks can be easily detected. Thus, a continuous audible and visual alarm signal is automatically activated in the pump room, engine control room, cargo control room, and on deck when the gas concentration reaches a predetermined level.
Wastewater Treatment
Wastewater treatment plants prevent pollution and diseases by treating wastewater before it is released into the environment. Toxic and flammable gases are released as a result of certain processes followed for water purification and are potentially dangerous at certain concentrations. Therefore, a reliable gas detection system is essential to protect personnel, stations, and the environment. The most common hazards are caused by:
Methane: usually produced during the decomposition of sludge. CH4 monitoring must be ensured in raw wastewater and sludge entering dewatering systems, anaerobic digesters, cogeneration, and wet/dry wells.
Hydrogen sulfide: H2S is both natural and a result of wastewater treatment. It is very important to control H2S in sewers, sludge dewatering systems, anaerobic digesters, and wet/dry wells.
Ammonia, Ozone, Chlorine: Toxic gases released during the decontamination phase of wastewater treatment plants. Gas detectors should be placed near storage tanks and processing areas.
Carbon dioxide: replaces oxygen, causing suffocation and affecting respiratory capacity. In wastewater treatment, it primarily results during sludge separation and biogas production.
Steel Industry
Steel and other metal production is one of the pillars of every economy. Despite technical innovations, workers in the steel industry face significant security risks when dealing with hazardous materials in furnaces, rolling mills, and foundries. Given the numerous risks posed by toxic and explosive gases, dust particles, and heat, which are not completely prevented, workers must always wear protection. Any additional risk must be avoided.
One of the greatest risks in steel and metal production is exposure to high concentrations of CO. Exposure to CO can be enough to cause permanent heart and nervous system damage. During steel production, numerous toxic and explosive gases are released. This requires constant monitoring of the environment using robust gas detectors. Additionally, simultaneous generation of hydrogen can contaminate the CO sensor in gas measurement devices and lead to false alarms. This can trigger a costly production interruption or even endanger lives (if workers become accustomed to ignoring the alarm signal, then a real alarm may no longer be taken seriously). Furthermore, methane represents a potential catastrophic explosion risk for both personnel and the factory. Therefore, steel manufacturing processes, metal melting and casting, and maintenance work must be constantly inspected and monitored for concentrations of toxic and explosive gases.
Mining and Tunnel Construction Industry
Tunnels and, in particular, mines are environments with a high potential for danger, so effective equipment for worker safety in underground networks can save lives. In mining operations and tunnel construction, explosives are used to blast through hard rock. Due to toxic gases resulting from explosions or other mining activities such as drilling and construction, underground environments are particularly hazardous. Mineral gases are highly concentrated and toxic, posing a threat to both worker health and the environment, and also limiting visibility.
Dangerous equipment and toxic gases in underground tunnels expose the mining industry to the risk of workplace fires. A fire in an underground gallery can be fatal, especially as work occurs in confined spaces with limited ventilation systems and evacuation routes. The presence of methane in tunnels also involves the risk of a catastrophic explosion. Therefore, atmospheric monitoring and effective ventilation are priorities for safety. Gas detectors help protect personnel from low oxygen levels or potential gas leaks.
Battery Charging Stations
When batteries are charged, they produce hydrogen, which is explosive at certain concentrations in the air. Many workers may not realize the danger of batteries, as it is a common activity. However, the hydrogen generated during battery charging and sulfuric acid in the battery are hazardous. If a worker comes into contact with sulfuric acid, their skin may burn, and if the acid splashes into the eyes, is inhaled, or ingested, the injuries can be severe. As with any corrosive chemical, appropriate handling procedures must be followed to avoid contact with it.
In addition to hydrogen, battery charging also generates oxygen, both of which can cause adverse effects. However, in the distribution environment, air quality is often overlooked, especially in older or outdated safety stations. Thus, if the hydrogen level exceeds 4% of the volume of the area, the overall atmosphere can become explosive. Therefore, hydrogen concentration should never exceed 1% of the available volume (adequate ventilation is required to keep hydrogen levels below 1%).
Depending on the composition of metal alloys in lead-acid batteries, a charged battery can generate two highly toxic byproducts: AsH₃ and SbH₃. Generally, these metal hydrides are present in small quantities but increase the need for ventilation systems to prevent an explosion. Also, open flames, cigarettes, or other ignition sources are not permitted in the area.
Equipment
PQ Series
The "PQ" series fixed gas detectors are designed and developed for demanding industrial conditions to perform continuous measurements of flammable, toxic, asphyxiant gases, and volatile organic compounds (VOCs) in the environment.
With ATEX/IECEx certifications, SIL2 (Safety Integrity Level 2), approved for performance according to EN 60079-29:1, and having a high ingress protection class, the detectors have proven their suitability for harsh environmental conditions.
The PID, Pellistor, electrochemical, infrared, and semiconductor sensors used in the "PQ" series provide excellent performance in LEL, ppm, ppb, and VOL ranges. The "PQ" series is divided into PQD (with display) and PQN (without display) ranges.
P Series
The "P" series fixed gas detectors, certified ATEX/IECEx, are designed and developed for the demanding conditions found in industrial stations, aiming to continuously measure toxic, explosive gases, and oxygen in the air.
Pellistor, electrochemical, and infrared sensors used in the "P" series detectors provide excellent performance in LEL (Lower Explosive Limit), ppm, and VOL ranges.
Continuous measurement of toxic and explosive gases is safe in hazardous environments due to the explosion-proof enclosure. The detectors carefully monitor the analog output signal level continuously to match the measurement level before transferring it to the panel. It adjusts the signal level in case of any deviation and generates an error signal if the adjustment fails.
PE Series
The "PE" series gas detectors, certified ATEX/IECEx, are designed and developed to detect explosive compounds in numerous applications.
Catalytic sensors used in the PE series offer excellent performance in the 0-100% LEL range.
The "PE" series operates perfectly in harsh environmental conditions, with an IP65 protection class. Continuous gas measurement is safely conducted in hazardous areas due to the explosion-proof enclosure.
The durable catalytic sensors allow precise measurement.
PE-KAYO Series
The "PE-KAYO" series is specially designed for fueling stations (gas stations). The detector includes a special accelerometer chip that monitors physical impacts that may occur at the location where the device is installed, along with fuel measurement functions. If a vehicle or truck hits the detector or the mounting support, the device can trigger an alarm to stop the fueling.
Additionally, the catalytic sensor used in the PE-KAYO series provides excellent performance in the 0-100% LEL range.
PC3 Series
The "PC3" series gas detectors are designed to reliably detect flammable, toxic compounds, and oxygen in light industrial environments. These detectors are classified for Zone 2, Category 3. Electrochemical and catalytic sensors ensure precise and sensitive measurement. The detector calibration can be performed automatically using values recorded in the detector’s software.
BTN Series
The "BTN" series gas detectors are designed to reliably detect combustible, toxic gases, and oxygen in bright and unclassified areas, offering a cost-effective solution.
High-quality catalytic, electrochemical, and semiconductor sensors used in the "BTN" series provide excellent results in LEL, ppm, and VOL ranges.
Comprehensive Services, Turnkey Projects
For hazardous gas (toxic and flammable) detection systems, AVITECH offers a complete range of services: Consulting and Design, Equipment Supply, Installation Works Execution, Programming, Maintenance and Technical Support.
We place special emphasis on integrating newly installed systems with existing ones: Fire Detection Systems, Public Address Systems, Inert Gas Fire Extinguishing, Foam Fire Extinguishing, Water Fire Extinguishing, Water Mist Fire Extinguishing, Aerosol Fire Extinguishing.
FAQs
Investing in a gas detection system is essential to prevent serious accidents, including explosions and poisonings, which can have devastating consequences on personnel health and equipment integrity.
Gas detectors are specially designed to measure the concentrations of hazardous gases in various industrial environments. In the pharmaceutical industry, they protect workers from exposure to hazardous chemicals, while in the food industry, they monitor carbon dioxide levels to prevent poisoning.
AVITECH offers a complete range of services, including consulting, design, equipment supply, installation, programming, maintenance, and technical support, ensuring efficient integration of gas detection systems with other existing security solutions.
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