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.

Due to the risks associated with oxygen depletion, companies are re-examining ways to keep their workplaces safe. Additionally, state and federal regulations have become more stringent, making oxygen depletion sensors a priority in your gas detection system. Here are some beneficial aspects of oxygen sensors you may not be aware of.

Detection Analysis

When it comes to electrochemical toxic gas sensors, one of the most useful features is detection analysis. With this feature, you can read analyze various electrical currents that are produced by oxidation. By doing so, the sensors can perform a detailed analysis of various types of equipment, enabling them to detect current or future problems before they turn into disasters.

While an alarm controller or siren will alert you to a gas leak or malfunction, the analysis feature ensures that your operation will continue unhindered. By having a constant check on the levels of oxygen in your area, your maintenance personnel can have the accessibility needed to make necessary repairs or equipment replacement.

Accurate Configuration

Being able to rely on accurate configuration is necessary for any facility, especially for on-site supervisors and safety engineers who may be located in monitoring centers miles from the facility. Through the use of specialized sample container units, an electrochemical gas sensor can help offsite monitoring systems the ability to stay ahead of dangerous conditions.

For example, sensors can provide timeline displays that show fluctuations in oxygen concentrations, giving technicians the ability to find the core problem. In the same way, oxygen sensors can also be calibrated to measure concentrations of hazardous substances at the same time. Not only do these functions keep the workplace safer, but they also allow monitoring centers to alert supervisors should a crisis occur that warrants evacuation.

Undetected Leaks

Above all, having a gas sensor to monitor the oxygen level in the air is vital to helping you find leaks in pipes, valves, or other areas where it may be difficult for other sensors to do so. Along with confined spaces, research labs, utility stations, and various types of processing and manufacturing facilities continued to need 24/7 monitoring.

By being able to find undetected leaks, your sensors will allow your safety processes to remain accurate and reliable when compiling data. Keeping a tab on nearby gas leaks will also help provide data in real-time to safety engineers. This ability to monitor the amount of oxygen in a specific area helps protect employees, especially when engineers need to determine the best course of action to escape harm.

Keeping a Tab on Your Facility’s Gas Levels

Along with being able to monitor specific equipment, oxygen depletion systems allow industrial operations the ability to keep a constant check on all of the toxic and inert gases in their vicinity. From offshore drilling platforms to confined spaces within chemical processing plants or refineries, an oxygen depletion sensor is a vital component of any gas detector.

Would your facility benefit from a sensor calibrated to measure a room’s oxygen levels? Get in touch with our team for a solution to meet your needs.

 SGX Sensortech

 Although this company is only four years old, it has quickly found itself with one of the best reputations in the industry. Specializing in industrial air safety, SGX has developed sensors that not only detect very low levels of dangerous gases, but do so while using far less power than sensors made only a few years ago. In fact, SGX sensors use less than 50 percent of the power once needed to get the job done, allowing companies to save even more on energy costs in addition to increasing workplace safety.

 Delphian

 Specializing in sensors made particularly for the oil and gas industry, Delphian has also been recognized for its innovative technology. Designing an electrochemical gas sensor that adapts very well to harsh work environments, the company’s sensors can be found on offshore platforms and drilling rigs around the world. In addition, they are also found in petrochemical and chemical plants, natural gas plants and refineries, gas storage and loading facilities, and pipelines and compressor stations. Along with its large product selection, the company is also known for providing in-depth knowledge of its sensors to customers in an easy-to-understand fashion, making it a very popular company within the oil and gas industry.

 MSA Safety

 A company born out of a mining explosion in 1912, MSA Safety has been an industry leader when it comes to keeping workers safe. Long known for its emphasis on research and development, the company has made great strides in developing many of the most popular portable gas sensors in use today. Along with this, MSA sensors are also used extensively in manufacturing facilities, processing plants, and offshore drilling platforms where workers spend much of their time in confined spaces. With many of the company’s products having been recognized for their durability in the workplace, MSA sensors are used by companies across the globe.

 Emerson Process Management

 A company known for producing an electrochemical gas sensor that is durable and also compatible with numerous types of transmitters, Emerson Process Management has a great track record when it comes to industrial safety. With its sensors being very simple to operate as well as cost-effective, the company is a top choice of many manufacturing facilities around the world. In addition, EPM sensors also have an extremely low power consumption and the ability provide workers with instant data, which can lead to many lives being saved.

Pros

Accurate & Reliable

Equipped with some of the most advanced leak detection technology available an electrochemical sensor remains one of the most accurate devices on the market. Their sensors have the ability to detect harmful gasses in the range of parts per million. This means if there is one part harmful gas to 999,999 parts normal oxygen, the sensor will be able to detect and alarm you of this danger. This translates to an extremely sensitive and precise gauge that will alert workers nearby before it is too late.

Efficient

Electrochemical sensors are well known throughout the industry for their efficiency. They have a low energy output using a minimal amount of electricity. They are an extremely cost-effective piece of equipment to use. Despite this they maintain a high resolution and are very easy to read regardless of the amount of natural light available. Additionally, these sensors can self-calibrate enabling them to be extremely accurate and reliable even under harsh working conditions.

Portable

Most of today’s electrochemical sensors are equipped with the technology allowing them to be used as a part of a wireless network. This means they can be connected to laptops, tablets or smartphones. With today’s tendency to have all key personnel equipped with mobile devices while on the job, the portability of electrochemical sensors translates to greater safety for everyone.

Cons

Limited Lifespan

These sensors might be very reliable and accurate but more often than not they need to be replaced on a regular basis. On average an electrochemical sensor needs to be replaced every two to three years in order to remain as effective as possible. Extreme temperatures and low humidity can dry out the electrodes in the device thereby shortening its lifespan. Luckily, they are a relatively inexpensive piece of equipment to replace.

Ultra-Sensitive

While most electrochemical sensors perform well under harsh working conditions, they are extremely sensitive to temperature fluctuations. In cases where the temperature can shift dramatically between high and low, the sensor can produce a false alarm. This swing may require the sensor’s calibration settings to be reset. That’s why this type of gauge is best suited to an area where the temperature is likely to remain within a limited range.

False Alarms

Electrochemical sensors are sensitive to interfering gases thereby causing the gauge to issue a false alarm. Substance specific electrochemical sensors are designed to only detect and measure particular gases. But in some cases with the presence of other gases, the sensor will give a false reading.  As you can imagine this poses a serious problem in any work environment. If a sensor gives a false warning, the building or surrounding area must be completely evacuated. Work will be halted until safety personnel have deemed it safe to return.