What Should a Gas Detector Have?

Deciding whether you need a gas detector or not shouldn’t be the question. If your facility handles materials that can adversely affect your health in the case of a leak, a gas detector is non-negotiable. As you start to research the different types of detectors, make sure these features are included.

1. Sensor Life Indication
2. Optional outputs
3. Smart Sensor Technology

1) Sensor Life Indication

How would a technician know when a sensor would need to be replaced if there is not a ‘visible expiration date’ on it? Typically a person would need to know how to look for tell-tale signs of sensor response to the target gas to be able to determine sensor life. This is a very tedious practice at best and subjective at worst. In order to eliminate the ‘human error’ and speed up the maintenance process, the sensor life indication has been made available. This takes guessing out of determining sensor life as well as reduces the cost of replacing sensors prematurely. 

There are 2 different ways to derive sensor life indications. One way is based on a simple timer. Companies determine a rough estimate of how many days and/or hours a sensor will last and use a general number as a count-down.

However, this method does not take into consideration what the sensor was exposed to and how many times. A better and more accurate way to determine sensor life is by actually measuring the sensor response to the calibration gas and converting the response to a meaningful display for the user. Displaying sensor life this way will take all guessing out of decision making, reduce inventory, and speed up maintenance.  

2) Optional Outputs

One of the most important options in a gas detector is the availability of signals and signal types. Detector outputs allow the detector to communicate or otherwise signal a monitoring device of an upset. Typically 4-20mA signal is used in the Oil and Gas industry, however, other communication protocols have been accepted by customers. Sometimes while a standard communication protocol is specified, i.e. 4-20mA, an additional mode of signaling is preferred, i.e. relays and/or digital communication protocol like Modbus. The detector you select, should give you both types of options and not have to make you select one over the other.

3) Smart Sensor Technology

Industrial gas detectors should be equipped with smart sensor technology. Smart sensor technology allows users to track information like installed date, born-on date, calibration intervals, and sensor life indication. Features such as these, allow users to have more information readily available in reference to their maintenance plan and detectors.

Accuracy & Reliability is Key

Investing in a gas detector for your facility is one of the best first steps to ensuring that your workers are safeguarded from danger. We’re proud to offer various detection systems equipped with design features such as magnetic switches, making it easy for engineers and technicians to perform calibration and configuration. It’s our goal to provide gas detectors that are both easy to maintain and adaptable for the toughest work environments.

Do you regularly work in areas where toxic and/or combustible gases are present? Get in touch with our team for a customized solution today.

Common Toxic Gases to Monitor

According to recent reports, there were a total of 19,190 warehouses in operation across the United States in 2020. From the creation of products to the storage and distribution of completed goods, the everyday process of any warehouse involves being around toxic chemicals and gases. Take a look at the three most common types of toxic gases found in warehouse facilities.

1. Carbon Monoxide (CO)
2. Carbon Dioxide (CO2)
3. Oxygen Depletion (O2)
4. Refrigerants

1) Carbon Monoxide (CO)

Carbon monoxide is believed to be one of the most common toxic gases on earth and is almost entirely a man-made gas. Often called the “silent killer” due to being absent of both color and odor, carbon monoxide can be lethal in even small concentrations. It is often used in metal fabrication, chemical manufacturing, pharmaceutical manufacturing, electronic applications, and is often emitted from coal, gas, and diesel engines. 

2) Carbon Dioxide (CO2)

Commonly found in the atmosphere, carbon dioxide is a natural byproduct of human and animal breathing, fermentation, chemical reactions, and the decomposition of plants and animals. It is a highly toxic gas that is both colorless and odorless but has a slightly acidic taste. Although it is a natural part of our life, it can be dangerous in high concentrations especially in areas that are poorly ventilated. It is often used in the manufacture of cast molds for metals, welding processes, pharmaceuticals, plastics, food processing, and cleaning supplies. 

3) Oxygen Depletion (O2)

Oxygen is what we need to breathe. While we normally breathe air that is 20.9% oxygen by volume under normal conditions, the presence of toxic gases can create disastrous consequences if oxygen levels don’t stay balanced. When certain circumstances reduce the amount of oxygen that we have to breathe, we can start to feel the adverse effects. Circumstances that may reduce oxygen include leaking materials from storage tanks, higher levels of toxic gas, decomposing organic compounds, corrosion, or fermentation. 

4) Refrigerants

Different refrigerants are used in warehouses to cool the warehouse and/or coolers within the warehouse. These refrigerants range from Ammonia, to Difluoromethane and everything else in between. Refrigerant leaks can be dangerous to humans, via asphyxiation and/or toxicity as well as as being active greenhouse gases which have negative impact on the environment. Some of the gases are also considered combustible and therefore pose an explosive and/or flammable danger.

Gas Detectors You Can Trust

Toxic gases unseen by the human eye pose a number of health risks, especially if exposure limits are left undetected. GDS Corp is proud to serve a number of different industries across the country with reliable gas detection systems. We consider it our personal mission to provide toxic and combustible gas detectors which will safeguard your warehouse and keep your manufacturing processes in operation long term.

Get in touch with our team for a fully customized detection solution that you can trust.

While typical background values of CO2 are non-toxic, higher concentrations can cause headaches, sleepiness, increased heart rate; concentrations above 5000 ppm can lead to oxygen deprivation, brain damage, and death.

Many seemingly innocuous industrial processes can create large quantities of CO2. For example, brewing and bottling can create vast amounts of CO2 from fermentation. Since CO2 is odorless and colorless, a slow leak into a confined area may not be detected before the atmosphere becomes deadly due to a lack of oxygen.

If a carbon dioxide gas buildup occurs in any area of an industrial facility or laboratory, it must be detected quickly. Industrial users need to make sure they have reliable CO2 detectors installed in confined spaces and in close proximity to valves, fermentation vats, and other sources of leaks.

Working Principle

CO2 sensors use the same operating principle as infrared hydrocarbon detectors. They create a beam of infrared light tuned to a specific frequency that is readily absorbed by CO2 molecules. The primary difference between an infrared CO2 detector and an infrared hydrocarbon detector is the choice of filter and infrared wavelength. Since each molecule of CO2 absorbed some of the infrared light, the amount of absorption is proportional to the percentage of CO2 present in the ambient air. Modern detectors utilize dual IR beams to compensate for changes in air pressure, temperature, drift, and dirt on the lens. More expensive CO2 detectors use sapphire windows to protect the IR transmitter and receiver elements from damage by any corrosive gases that may exist in the ambient environment.

Features of a CO2 Gas Detection System

Any good CO2 detection system consists of one or more detectors and a central controller that can monitor each detector and provide common warning and danger alarm indications using horns or flashing strobes.

• Multiple Detector– Since all facilities are different in terms of size and layout, multiple types of CO2 detectors must be available for use. Ambient detectors sense the presence of CO2 in the vicinity of the detector by diffusion. Sample
  draw detectors use a dedicated pump to pull air samples from remote locations where the use of ambient sensors is not feasible.
• Controllers – Any system with more than a single CO2 monitor will likely require a controller to power the sensors and monitor the outputs to create alarm indications as needed. Controllers are often configurable to allow users to select
  the proper number of channels while allowing upgrades in the future.
• Wireless Technology – As technology has advanced, most industrial facilities now employ wireless technology with their monitoring systems. Wireless CO2 detectors that operate on batteries are now available that use very-low-power infrared detectors.

Protect Your Facility

Since dangerous gas buildups can occur in virtually any facility, having the proper monitoring system in place can make all the difference regarding worker safety. If you regularly work with carbon dioxide, make sure you have a sensor that measures CO2 levels in your vicinity. By being one step ahead of toxic leaks or equipment failure, your manufacturing processes can continue running without interruption.

Get in touch with our sales team to learn more about our selection of CO2 sensors and custom gas detection systems.

While catalytic bead sensors have been in use for many years, infrared sensors are gaining popularity due to their increased reliability and longer life. Understanding the differences between these two major technologies is important as you determine how to configure your gas detection system. In the case of methane gas, it’s crucial to have a sensor you can rely on in your specific environment.

What is Methane Gas?

Did you know that natural gas is made up of nearly 87% methane? Like other combustible materials, methane gas is highly flammable and presents a huge risk for those dealing with natural gas. In its organic state, it is odorless, colorless, tasteless, and nontoxic. As a major greenhouse gas, it is produced during the anaerobic decomposition of manure or in the production of chemicals such as acetylene and methanol.

As a component of natural gas, it is known to rise and accumulate in certain areas of enclosed buildings. If a sufficient amount is present, it will replace the oxygen and may create a long term asphyxiation hazard if allowed to accumulate. If the percentage increases beyond five percent by volume, it becomes a very dangerous explosive mixture. 

Unsafe Levels of Methane

Methane gas that has not been odorized can be very difficult to detect without proper combustible gas detection equipment. According to biotechnology scientists, methane gas has not been shown to be toxic but can cause an explosion (the Lower Explosive Limit)  when one volume of methane is mixed with 20 volumes of air (~5% by volume). With that in mind, a gas detection system can be configured to measure the LEL value in real time. Typically, gas detection systems are programmed to generate a warning if the measured value reaches 20% LEL and an alarm if the measured value reaches 40% LEL. 

Catalytic Bead vs. Infrared Sensor

If you regularly work with methane, a byproduct or component, it’s important to understand the two types of sensor technologies used to detect methane gas.

• Catalytic Bead Sensors – Preceding the use of infrared sensors, catalytic bead sensors usually cost less and have the ability to detect other combustible solvent vapors in the environment. Working as a Wheatstone bridge circuit, the active filament wound in a catalytic bead sensor uses a platinum wire with a palladium-based catalyst. Unsafe levels of methane are detected when the resistance ratio between the active and reference bead changes.

• Infrared Sensors – Due to the risk of catalytic bead poisoning in environments involving silicone, lead, sulfur, or halogenated compounds, infrared sensors were introduced as an alternative. Using two wavelengths of infrared energy, infrared technology compares the  outputs of the gas absorption beam and reference beam to determine if gas is present. Because infrared sensors don’t require oxygen to operate, they can be reliably used around a number of applications without issue. Furthermore, typical infrared sensors include a microprocessor that continuously checks the sensor for proper operation. 

Pro Tip: Methane gas is often combined with an odorant that smells like rotten eggs to help you detect leaks. If you smell a peculiar odor, be sure to survey your equipment or call for assistance.

Real-Time Detection

Both catalytic bead and infrared sensors can be configured to detect methane gas, and both have certain advantages. GDS Corp offers gas detectors that utilize both technologies to give you accurate information no matter what environment you’re in.

Connect with our sales team to customize a methane detection system for your particular

In the early days of gas detection, instruments were designed to detect a single gas. Most facilities, however, contain a number of gases in any one location vicinity and have a need for dual-channel gas monitors. Today, thanks to advancements in sensor technology and electronics miniaturization, gas detection systems can now measure both toxic and combustible gases at the same time. 

Types of Hazardous Gases

To better understand the power of a dual-channel gas detector, it’s important to note the difference between each hazardous gas, namely toxic and combustible.

• Toxic Gases – Usually emitted from specific chemicals, toxic gases can be found in various environments and are potentially lethal if inhaled. Most toxic gases are colorless and invisible, making them extremely dangerous for facilities that do not have sufficient monitoring systems.
• Combustible Gases – In the presence of oxygen and an ignition source, combustible gases can create sudden flashes of fire or explosions. In addition to causing extreme bodily harm, combustible gases pose a number of risks for equipment and facilities. 

Pro Tip: It’s important to note that certain gases are lighter than air, others are heavier and some remain at “nose level”. This may require that each sensor be located in a different location for maximum efficiency. Properly designed dual-channel detectors support both local and remote sensors for this reason. 

Technology Behind Dual Channel Gas Detectors

Pioneers in gas detection produced sensors that accurately measure the concentration levels of specific target gases in the atmosphere, and this remains true today. However, all toxic and combustible gas sensors have a ‘cross-sensitivity’ to certain gases that are similar in chemical makeup. So a chlorine sensor, for example, will also detect bromine gas, and a catalytic bead sensor calibrated for methane will also detect propane, ethylene and almost any hydrocarbon. 

So in cases where only combustible gases are found, a single detector calibrated for the most combustible gas may be sufficient. But if both methane and hydrogen sulfide might be present, for example, then separate sensors for hydrogen sulfide (a toxic gas) and methane (a combustible gas) should be installed. 

In a properly designed dual-channel gas detector, two sets of independent sensor inputs and analog outputs share a common display and user interface. Channels should operate independently and offer unique alarm levels and calibration capability. 

Installation and Operation of Dual Channel Gas Detectors

Depending on your model, GDS Corp dual-channel gas detectors can support two toxic sensors, two combustible sensors of any combination of both. Both sensors can be installed on the gas detector display unit itself (Called “local sensors”) or in a separate housing that can be mounted some distance away from the display (“Remote sensors”).

In the case of the hydrogen sulfide / combustible gas detector, the hydrogen sulfide sensor would be mounted within 18” of the floor, and the methane sensor within 18” of the ceiling. 

In confined spaces where oxygen levels may be low, a remote sensor should be mounted approximately 5” to 6” above the floor. 

Keep Your Facility Protected

If you regularly work with a large number of hazardous gas, it’s crucial to have comprehensive safety equipment. GDS Corp offers a number of dual-channel gas detectors that can be customized for your specific environment. 

Connect with our sales team to find a gas detection solution to keep your facility safe and protected.

Common Types of Harmful Gases

Gas detection experts have defined a toxic gas as “one which is capable of causing damage to living tissues, impairment of the central nervous system, severe illness or, in extreme cases, death when it is ingested, inhaled, or absorbed by the skin or eyes.” Technically, gases are generally considered toxic if the median lethal concentration is greater than 200 parts per million (ppm). 

Depending on your industry, you may come into contact with numerous harmful gases on a daily basis. Examine the health effects of the following five common toxic gases:

1. Hydrogen Sulfide
2. Carbon Monoxide
3. Nitrogen Oxides
4. Ozone
5. Solvents

1) Hydrogen Sulfide

Primarily identified by its “rotten egg” smell, hydrogen sulfide (H2S) is found in a number of manufacturing processes and chemical substances. Products such as pesticides, plastics, pharmaceuticals, landfills, and even breweries emit hydrogen sulfide as a byproduct. The toxicity levels of hydrogen sulfide emissions are dangerously high, especially if not disposed of properly. Inhalation of high concentrations of H2S can result in irritation, unconsciousness, memory loss, or in severe cases, instant death.

Severity Level: OSHA currently recommends a 10-minute ceiling level of 10 ppm for workers. In addition, 100 ppm of H2S exposure has been proven to have immediate lethal consequences, making it highly toxic, even at these low concentration levels.

Pro Tip: Install an H2S gas detector to monitor specific levels of H2S concentration in your vicinity, no matter what other gases may be present.

2) Carbon Monoxide

Generally found in industrial processes as a source of energy and reducing agent, carbon monoxide (CO) is a tasteless, odorless, and colorless gas. When materials are burned improperly, the emissions of carbon monoxide are highly poisonous, especially in crowded areas where human exposures can’t be monitored. Health effects such as nausea, restlessness, and euphoria may be experienced with repeated exposure causing eventual death. 

Severity Level: OSHA currently recommends 50 ppm for workers during an 8-hour time period, and maritime workers may need extra attention if the CO concentration is greater than 100 ppm. Concentration levels beyond 200 ppm are considered highly dangerous.

3) Nitrogen Oxides

Nitrogen oxides encompass seven different gases, with nitric oxide and nitrogen dioxide being the two most common forms. Found in a number of consumer and industrial environments, nitrogen oxides are the main contributor of air pollution and reduced air quality. Nitric oxide is often emitted from vehicles, agricultural processes or as a byproduct of combustible fossil fuels, and nitrogen dioxide has been used in the production of rocket fuels and explosives. According to the CDC, health effects vary from eye, skin, and respiratory tract irritation to acutely lethal circumstances.

Severity Level: Health officials are constantly trying to find ways to limit exposure to nitrogen oxides. The current permissible limit for nitric oxide is 25 ppm within an 8-hour work shift, with 100 ppm being immediately lethal. Comparatively, nitrogen dioxide has a 5 ppm permissible limit and 20 ppm lethal concentration limit.

4) Ozone

Especially toxic to plant life and humans, ozone is a gas made up of three oxygen atoms (O3) and is usually seen as widespread smog across cityscapes. While it may occur naturally in the upper atmosphere of the stratosphere, chemical reactions resulting from vehicle exhausts or gasoline vapors contribute to large ozone concentrations at ground level. Health problems such as decreased lung function, respiratory infection, UV overexposure (i.e. sunburns) or skin cancer in humans make it a toxic substance that must be monitored continually.

Severity Level: According to OSHA, ozone levels should never exceed the following average: 0.10 ppm (parts per million) for 8 hours per day exposure. While the level of work may contribute to the actual level, extreme caution must be administered when working near ozone for an extended period of time.

5) Solvents

In addition to being highly flammable, the properties of organic solvents are highly toxic. Organic solvents are carbon-based substances capable of dissolving or dispersing one or more other substances. Solvents usually found in kerosene, gasoline, paint strippers, and degreasers are highly flammable and at high concentrations, can affect your central nervous system. Other side effects such as dizziness, drowsiness, lack of concentration, confusion, headaches, coma, and death can be experienced during long term exposure of solvents.

Severity Level: Due to the various forms of solvents used on a daily basis, OSHA has published individual guidelines for every toxic chemical gas that has been identified. Review the standards of the toxic gases you may encounter to protect your long term health.

Protecting Your Health

When the health of your employees is at risk, measures must be put in place to ensure safe working conditions. GDS Corp offers a wide range of electrochemical sensors and photoionization detectors (PID) that can detect the presence of toxic gases at very low levels. Equip your facility with protection you can rely on with detection customized and tested for your hazardous environment.

Connect with our gas safety experts to find the best detection system for your facility.