Installation and Placement Guide

Fixed gas detection systems play a vital role in many industrial settings. They act as the silent sentinels, constantly monitoring the air for leaks of hazardous gases. But for these systems to work effectively, proper installation and placement are crucial. A misplaced sensor can mean the difference between early detection and a potential disaster.

In this blog post, we’ll look into the key considerations for installing and placing fixed gas detection systems:

Assessing the Threat

Before installing a fixed gas detection system, a comprehensive risk assessment is an essential first step. This process serves to identify and localise potential atmospheric hazards within your facility, ensuring the optimal placement and efficacy of the chosen detection system.

Analyse Inventory

• Chemical Scrutiny: A detailed inventory of all chemicals stored, processed, or generated on-site should be established. Safety Data Sheets (SDS) for each chemical serve as a vital resource, providing crucial information regarding health hazards, including the potential for gas releases.
• Process Evaluation: A thorough analysis of the various processes employed within the facility is paramount. For instance, welding operations often generate fumes containing hazardous gases such as carbon monoxide and nitrogen oxides. Similarly, chemical reactions utilised in manufacturing might release vapours or by-products that pose a risk.

Tailoring Detection Strategies

Following the identification of potential gas hazards, a classification system based on their key properties should be implemented:

• Density Classification: Categorise gases based on their relative density to air. This will determine the best position for your fixed gas detection system.
• Toxicity Assessment: The potential harm a gas poses to human health is a critical factor. Highly toxic gases, like chlorine, require heightened vigilance and potentially more sophisticated detectors due to their ability to cause harm at exceptionally low concentrations.
• Flammability Evaluation: Determine whether the gas is flammable or explosive. For facilities handling such materials, early leak detection is crucial to prevent fires or explosions. Placement of additional detectors near potential leak points, such as valves and flange connections, might be warranted.

Risk Assessment: Prioritising High-Leak Probability Areas

Leak potential varies throughout a facility. Focusing on areas with a statistically higher likelihood of leaks optimises detector placement and resource allocation:

• Storage Tank Vulnerability: Leaks can originate from valves, fittings, or tank corrosion. Strategic detector placement includes downwind locations (considering prevailing winds) and near tank vents.
• Piping and Valve Scrutiny: These components are common leak points due to wear and tear. Install detectors near flange connections, valves, and throughout piping runs, with a particular focus on junctions and bends.
• Process Equipment: Potential Release Points: Pumps, reactors, and other processing equipment can develop leaks due to malfunctions or faulty seals. Place detectors close to these areas, particularly targeting potential leak points identified during the risk assessment.
• Confined Space Considerations: Confined spaces like pits, vaults, and tanks can trap hazardous gases. Ensure proper ventilation and consider incorporating portable gas detectors into confined space entry procedures.

Industry-Specific Considerations

Stay safe in the workplace by being aware of dangers like natural gas, propane, chlorine, and carbon monoxide. These substances pose industry-specific risks that can harm your health and safety. It is important to be cautious and take necessary precautions to prevent accidents and injuries.

By staying informed and following safety guidelines, you can protect yourself and others from potential hazards. A drug plant needs detectors for ammonia in refrigeration, while a paint factory needs monitoring for VOCs from solvents.

By identifying atmospheric hazards, classifying their properties, and pinpointing high-risk leak areas, you’re establishing a foundation for an effective fixed gas detection system. This proactive approach safeguards your workers and facility by preventing incidents before they occur.

Location, Location, Location

The placement of your gas detectors depends on the type of gas they’re monitoring:

• Lighter than Air: For gases like hydrogen and methane, which rise like balloons, install detectors high up, near ceilings or in corners where pockets of gas can accumulate.
• Heavier than Air: Denser gases like propane and gasoline sink. Place these detectors low, within a few inches of the floor.
• Similar Density: For gases with a density close to air (like carbon monoxide), the breathing zone (around 4-6 feet from the floor) is the ideal spot.

Keep it Clear: Avoiding Obstructions

Gas detectors need a clear path to sniff out leaks. Avoid installing them behind equipment, pipes, or storage containers. This can hinder their ability to detect gas and lead to delayed warnings.

Beyond the Basics: Additional Considerations

• Airflow: Consider air circulation patterns. Don’t place detectors near air intake vents where fresh air might dilute the gas concentration.
• Control Panels: Locate control panels in safe areas outside the hazardous zone but ensure they’re easily accessible for monitoring and evacuation procedures.
• Accessibility: Remember, detectors need regular maintenance and calibration. Ensure they’re positioned for easy access by qualified personnel.

Professional Help is Key

Installing and maintaining a fixed gas detection system is a complex task. Consulting with a qualified professional ensures your system meets all safety regulations and is placed strategically for optimal performance.

Follow these rules and get expert help to make sure your gas detection system protects your building and people from harm.

Rockall Safety has experts who can help you choose the best locations for installing your gas detection system. They offer site surveys and have a team of engineers specialised in fixed gas detection.

If you are unsure on the correct system to use, you can visit our fixed gas detection product page here, or you can give us a call and we can point you in the right direction.

Written by Emma Curthoys