Designing a Gas Detection System

INSTRUMENTATION
 Why Gas Detection?
Safeguard Life and Property.
Provide Early Warning of Hazardous Conditions.
Provide Opportunity for Evacuation and Notification from Re-entry
Provide Time for Intervention and Correction.
Trigger Facility Protection Systems.
Ventilation, Water Mist, Fire Suppression.

Satisfy Local Fire Code and Provide Insurability.

Address Real and Perceived Safety Concerns.
Note: Gas Detection is “Recommended Practice,” “Required by Code,” or
“Required by Law.”

2 INSTRUMENTATION
 Points to Consider
Understand the application
Identify potential danger points
Establish design goals
Determine gas characteristics
Profile the plant and potential release scenarios
Other elements in selecting gas detection systems
Actual placement of detection
Indoors
Outdoors

3 INSTRUMENTATION
 Understand The Application
The gases to be monitored
Toxic (STEL, TLV, TWA)
Combustible (LEL, UEL)
Exposure limits
Density and Other Gas Properties
Local and federal regulations
Uniform Fire Code
Code of Federal Regulations
Local Fire Marshal

4 INSTRUMENTATION
 Identify Potential Danger Points
Release Points – sensors should be placed as close as possible to potential leak
sources.
Seals and flanges, fittings and welds
Expansion joints and gaskets
Engine combustion
Storage, loading and unloading areas
Runoff areas
Decomposing materials
Receptor Points – a gas detection notification system should protect any person,
property or equipment that may come in contact with harmful gases.
Wind direction
Ventilation systems
Run off areas
Confined spaces
Communities and facilities

5 INSTRUMENTATION
 Establish Design Goals
Initiate a response based on an early warning of a potential problem.

 Notification or annunciation – method of warning

 Ventilation control
 Process shutdown
 Evacuation and emergency response
 Amount of confinement - over pressurization and accumulation
 Run-up distance – speed of flame increases with distance
 Amount of congestion or obstacles
 Fuel quantity and mixing
 Margin of safety – distance between leak source and receptors
 Plant safety process
 Insurance requirements

6 INSTRUMENTATION
 Determine Gas Characteristics

LEL, UEL, Toxicity

Vapor density
Density differences with temperature
Cryogenic liquids, flammable liquids
Low density gases displacing ambient density gases (helium vs. oxygen)
Gases under pressure will condense in areas where vented first
Gases changing composition – dry ice
Toxicity vs. flammability (MTBE 40 PPM 1.6% LEL)
Hydrolyzed (BF3, F2)
Pyrolyzed (NF3)
Flash point - the lowest temperature at which a liquid can form an ignitable mixture in air
near the surface of the liquid. The lower the flash point, the easier it is to ignite the
material.
Rate of evaporation and dispersion characteristics
Gas mixing (fuel, oxygen, ignition source)
Oxygen enriched environments

7 INSTRUMENTATION
 Gas Hazards
There are three main types of gas hazard

1. Flammable
Risk of fire and or explosion,
e.g. Methane, Butane, Propane

2. Toxic
Risk of poisoning,
e.g. Carbon Monoxide, Hydrogen Sulfide, Chlorine

3. Asphyxiant
Risk of suffocation,
e.g. Oxygen deficiency, Nitrogen, Carbon Dioxide

8 INSTRUMENTATION
 Flammable Risk
Fire Triangle
Three factors are always needed to cause combustion:

1. A source of ignition

en

he
2. Oxygen

yg

at
ox
3. Fuel in the form of a gas
or vapour
FIRE
fuel

9 INSTRUMENTATION
 Flammable Risk
The operation of a car’s choke
illustrates an important part of 100% v/v gas
flammable gas hazards 0% v/v air
All flammable gases are only ignitable
over their flammable range
too rich
Flammable gases tend to be measured
in percentage of their explosive Limit
(%LEL) U.E.L. (upper
explosive limit)
flammable
range
L.E.L. (lower
explosive limit)
too lean
0% v/v gas
100% v/v air

10 INSTRUMENTATION
 Toxic Risk
Some gases are poisonous and
can be dangerous to life at
very low concentrations.
Some toxic gases have strong
smells like the distinctive
‘rotten eggs’ smell of H2S
Others are completely odourless
like Carbon Monoxide

11 INSTRUMENTATION
 Toxic Risk
The measurement most often 1 million balls
used for the concentration of
toxic gases is parts per million
(ppm).
For example 1ppm would be
equivalent to a room filled
with a total of 1 million balls
and 1 of those balls being
red. The red ball would
represent 1ppm.
1 red ball

12 INSTRUMENTATION
 Profile the Plant and Potential Release Scenarios

Gas sensors should be placed to ensure that a quantity of gas will past by them in all
normal release scenarios.

Identify physical features of plant

Identify ventilation tracks
Identify escape routes
Protect entrances to areas
Mark escape routes
Identify wind directions

13 INSTRUMENTATION
 Other Elements
Accessibility for calibration and maintenance
Wiring and installation
Environmental conditions
EMI and RFI
Alarm levels
Exposure limits
Oxygen levels – some toxic gas electrochemical sensors require a minimum
oxygen level to function. All catalytic bead combustible detectors require
oxygen to work.
Be aware of poisoning and inhibiting factors

14 INSTRUMENTATION
 Interior Detector Placement Guidelines

Operate Detectors Within their Temperature Limits. Use Sample Draw or Duct Mount
Configurations When Needed
Water, Moisture, Dust and Dirt May Affect Performance. Minimize Exposure and Protect
From Adverse Conditions
Locate Detectors With Respect to Grade, Floor, or Operating Level - According to
Building Design, HVAC System, Characteristics of Potential Leak
When Monitoring Specific Equipment, Place Detectors Near (12 Inches) Pump, Seal,
Tank, Valve, etc.
Sensitivity of Detector Depends on Proximity to Leak. Adjust Alarms if Earlier
Annunciation is Required
Mount Detectors Securely, Independent of Vibration, With Weather Shield Facing
Downward
Conduct Smoke Trace Behavior Studies If in Doubt

15 INSTRUMENTATION
 Detector Spacing Indoors

There are Few Published Guidelines and No Standards Indicating Area or Volume
Effectively Protected By a Diffusion Sensor. There is a Corollary in Fire Protection
UL Suggests a 900 Ft2 Ceiling Space Per Smoke Detector, Which is a 30 Ft. Square or
15 Ft. Radius
Using This Base Guideline, the Total Number of Detectors Must be Based on
Gas Dispersion Characteristics and Air Movement
Potential Leak Source Locations and Characteristics,
Sources of Ignition Locations
Interior Space Division by Walls or Barriers
Economics of the Procurement

16 INSTRUMENTATION
 Detector Spacing Indoors, Cont’d.

UL Suggests a 900 Ft2 Ceiling Space Per Smoke Detector

15 Feet 15 Feet

30 Feet
Detector Detector

30 Feet
References
NFPA 72 E, Standard On Automatic Fire Detectors
Schaeffer, M.J., “The Use of Combustible Detectors in Protecting Facilities from Flammable
Hazards,” ISA Transactions, Volume 20, No. 2, Instrument Society of America 1981

17 INSTRUMENTATION
 Indoors
40 feet

Door

Ceiling
Ventilation Natural Gas
20 ft
S
T
O
R
A
G
Lab Bench
E

Cl2

Door
LN2

Window

18 INSTRUMENTATION
 Outdoor Detector Location Guidelines

Use same considerations outdoors as indoors.

Consider Angle and Direction of Prevailing Wind
The Orientation of Structures and Surrounding Terrain with Regard to Shielding
Affects
The Proximity of Large Quantities of Toxics to Personnel and Equipment, Which
May Require Added Detectors to Isolate the Two

19 INSTRUMENTATION
 Outdoor Detector Location Guidelines

Possible Entrapment of Leaking Gases and

Vapors Within Columns, Low Lying Areas or
Confined Spaces

Sources of Ignition and Processes With

Fugitive Leak Potential Are Considered for
Detector Placement

20 INSTRUMENTATION
 Outdoor Detector Location, Cont’d.
Heavier Than Air Gases or Vapors: Vapor Density >1
The Preferred Location for Detectors is ~18 Inches Above Grade. For Liquid Spills,
As Close to the Vapor/Liquid Interface as Possible, and Still Allow for Detector
Calibration
Lighter Than Air Gases and Vapors: Vapor Density <1
The Preferred Location for Detectors is About 6 to 8 Feet Above Grade or Operating
Level, With Special Attention Being Paid to Air Currents, Structures, Roofed
Areas, Etc.

21 INSTRUMENTATION
 Detector Spacing Outdoors
Few Guidelines Exist for Detector
Placement
An Increased Grid Density is Used Outdoor
Presumably Because of the Greater
Potential for Leak Dilution
Thus, More Detectors Are Required, and
Potential Leaks Are Encircled, to Account
for Wind Shifts

22 INSTRUMENTATION
 Detector Spacing Outdoors
 Repeat Outdoor Grid Pattern as Conditions
Warrant. Focus on Potential Leak Sources for
Additional Detectors if Required

Detector 10-15 Feet Detector 10-15 Feet

20-30 Feet

20-30 Feet

23 INSTRUMENTATION
 General Location
Considerations
Toxic Gases and Vapors:
Identify Potential Leak Sources, Work Areas, and Exit Points. Understand Where
People are Performing Their Work and Place Detectors Between Probable
Release Points and the Work Area

24 INSTRUMENTATION
 General Location
Considerations
Allow Access for Sensor Calibration and
Replacement.
Sensors Have a Finite Life - Calibrate and
Maintain Regularly!
Always Locate Detectors Using “Local
Conditions Knowledge,” and Lighter or
Heavier Than Air Principles

25 INSTRUMENTATION
 General Location
Considerations
Locate Detectors Within Their Temperature Rating
Avoid Exposure to Sources of High Radiant Heat
Keep Detectors Away From Moisture and Chemicals
Avoid Vibration and Mechanical Shock Hazards
Observe Recommended Wiring and Tagging Practices
Use Shielded Cable Whenever Possible and Follow Correct Grounding Practices
(NFPA 70)
Observe Proper Detector Mounting Orientation

26 INSTRUMENTATION
 Detector Location and Area Coverage Map
IMPORTANT
Detectors should be located close to any potential leak
source and between leak source and any potential source of
ignition existing at the monitored site.

XNX-Optima

FILL LINE

DETECTOR LOCATED ON
TOP OF TANK NEAR VALVE
OR FLANGE ON FILL LINE

FILL LINE

TANK SUPPORT LEGS

TOP VIEW OF STORAGE TANK

OUT FLOW

DETECTORS SHOULD BE LOCATED BELOW TOP OF DYKE WALL

FOR VAPORS THAT ARE HEAVIER THAN AIR.
Sensor should be approx 12-18 in above grade. These vapor densities
SIDE VIEW OF STORAGE TANK are greater than air.

27 INSTRUMENTATION
 TOP VIEW OF STORAGE TANK

Detector Location and Area Coverage Map

IMPORTANT
Detectors should be located close to any potential leak
source and between leak source and any potential source of
ignition existing at the monitored site.

XNX-Optima

FILL LINE

DETECTOR LOCATED ON
TOP OF TANK NEAR VALVE
OR FLANGE ON FILL LINE

FILL LINE

TANK SUPPORT LEGS

OUT FLOW

DETECTORS SHOULD BE LOCATED BELOW TOP OF DYKE WALL

FOR VAPORS THAT ARE HEAVIER THAN AIR.
Sensor should be approx 12-18 in above grade. These vapor densities
SIDE VIEW OF STORAGE TANK are greater than air.

28 INSTRUMENTATION
 Detector Location and Area Coverage Map
IMPORTANT: This is intended as a General Application Note and NOT as the sole source of
information in determining quantity and location for detector placement. Consult additional
resources when developing a monitoring system. Additional information is available for developing
Combustible Gas Detection systems, such as: The National Fire Protection Association, NFPA 52
and the Instrument Society of America, ISA-RP12.13-Part II-1987. Services are also available from
Professional Safety Engineering Firms and should be utilized whenever necessary

TOP VIEW OF THREE AND TWO TANK AREA

SIDE VIEW OF TANK

8
DETECTORS SHOULD BE
LOCATED BELOW TOP OF
DYKE WALL FOR VAPORS
THAT ARE HEAVIER THAN AIR.
Sensor should be approx 12-18 in.
4 5 6 above grade..

7
IMPORTANT
Detectors should be located close to
any potential leak source and between
leak source and any potential source of
ignition existing at the monitored site.

29 INSTRUMENTATION
 Detector Location and Area Coverage Map

TOP VIEW OF UNLOADING FACILITY

R.R. SPUR NO. 13

R.R. SPUR NO. 12

IMPORTANT
Detectors should be located close to any potential leak source and between
leak source and any potential source of ignition existing at the monitored
site.

NOTE: IF PIPING
FUNCTIONS OR VALVES ARE NOTE: DETECTORS SHOULD
ABOVE THE TANK CAR A BE LOCATED LOW, CLOSE TO
DETECTOR MAY BE GRADE FOR VAPORS THAT
MOUNTED PART WAY DOWN ARE HEAVIER THAN AIR.
THE WALL TO DETECT NOTE: Sensor should be approx.
FALLING VAPORS FROM A I I I I 12-18 in. above grade. These vapor
LEAK SOURCE densities are heavier than air.

SIDE VIEW OF UNLOADING FACILITY

30 INSTRUMENTATION
 Publications to Reference
Chemical Weekly, 2008, “Key Considerations when Designing a Gas Detection System”
ISA Recommended Practices
ACGIH: Annual TLV and BEI Guide
1330 Kemper Meadow Drive, Cincinnati OH 45240-1634
NFPA/ANSI Guides, Standards and Practices
1 Batterymarch Park, Quincy MA 02269-9101
NIOSH: Pocket Guide to Chemical Hazards
Available by FAX Request to (513) 533-8573
OSHA, CFR 29, Section 1910.1000, Subpart Z“Working in Confined Spaces.”
NIOSH1 Publication 80-106
“A Guide to Safety in Confined Spaces.”
NIOSH Publication 87-113
“ALERT: Request for Assistance in Preventing Occupational Fatalities in Confined Spaces.”
NIOSH Publication 86-110

31 INSTRUMENTATION
 The End

Questions?

32 INSTRUMENTATION