White Paper

Improving Safety by
Analyzing Gas Streams
in Ducts
Improving Safety by Analyzing Gas Streams in Ducts White Paper

Improving Safety by Analyzing Gas Streams in

Ducts
In situ systems for continuous monitoring of hazardous material
releases often fail in the harsh conditions found in gas streams.
External measurement systems using aspirators address these
reliability issues and provide improved performance.

Introduction
There are many situations in a variety of industries where it is necessary to use an
instrument to measure the concentration of specific components in a gas stream
flowing through a duct. Such instruments consist of a sensor and transmitter, both
packaged in a single housing. Measuring these components and acting upon the
readings can improve operations, ensure safety and aid in regulatory compliance in a
wide range of applications.
In many of these applications, in situ measurements are not a viable option because the
gas stream is at high temperature and is very corrosive, which results in fouling of the in
situ sensor and short operating life. This can be particularly problematic when sensor
replacement requires downtime in applications where uninterrupted operation is
essential, such as with gas turbines.
A better solution in these cases is to take a sample of the gas and send it to an external
instrument for measurement (Figure 1). There are a variety of ways to extract a sample
from the gas stream, with aspirators often the best choice for a number of reasons
which will be discussed throughout this white paper. Leading applications for this
approach will also be discussed, including measurement of gas streams in gas turbines,
sewage dryers, printing plants, and LNG tankers.

Figure 1: An alternative to an in situ measurement system is to send a gas sample to an external instrument
such as an aspirator system.

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Improving Safety by Analyzing Gas Streams in Ducts White Paper

But first, let’s compare in situ versus external measurements, looking at the pros and
cons of each approach.

In situ versus external measurements

In situ measurements are often preferred because the gas is sampled in the duct and
the speed of response is very fast. While this is typically the first approach attempted, it
does not work well when the gas stream is at a high temperature or is highly corrosive,
which is often the case.
In these types of applications, the instrument’s sensor comes into direct contact with
the process gas in the duct. This can cause it to foul or fail outright, rendering the
measurement invalid because the signal sent from the sensor to the instrument’s
transmitter is not correct.
In situ instruments often tend to be very expensive due to the requirement for designs
with some level of protection for the sensor from the gas stream. And even with this
protection, sensor fouling and failure is common.
Gas streams usually do not disperse homogeneously inside the duct due to
stratification or uneven mixing. As a result, the sensor may not detect the gas of
interest within the stream. Point gas detectors offer the smallest coverage, because the
inserted sensor heads are typically a small fraction of the cross-sectional length of the
duct (Figure 2). By contrast, open-path detector designs offer greater coverage of the
duct cross section (Figures 3 and 4).

Figure 2: Gas monitoring with duct-mounted point gas detector.

Figure 3: Gas monitoring with duct-mounted open-path detector, single-beam design.

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Improving Safety by Analyzing Gas Streams in Ducts White Paper

Figure 4: Gas monitoring with open-path detector, cross-duct design.

With external measurements, a sample stream is drawn off from the duct and sent to a
remotely-mounted instrument placed a safe distance away from the gas stream. The
main advantage of external measurements is much higher reliability than the in situ
approach because the instrument sensor and transmitter are mounted outside of the
duct. This reduces the cost of the measurement device substantially and greatly
extends the life of the instrument’s sensor since it is not exposed to high heat or

Figure 5: Sampling duct probe in a rectangular duct.

humidity. If an issue does occur, externally-mounted instruments and their sensors are
much easier to maintain or replace than their in situ counterparts as there is no
requirement to remove the sensor from the duct, which often requires a process
shutdown. With a sampling system, high detection coverage may be achieved by
inserting a duct probe able to span the long dimension of the duct cross-section
(Figure 5).

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Improving Safety by Analyzing Gas Streams in Ducts White Paper

The main issues with this approach are ensuring the sample arriving at the
measurement point is representative of the gas stream within the duct, and the sample
is delivered to the measurement point quickly. The latter issue can be addressed to
some extent by minimizing the distance from the point where the sample is taken to
the instrument’s sensor, and by using an instrument with a very fast response time.
Both issues can be addressed in most applications by using the right sampling system.

Aspirators versus other types of sampling systems

As mentioned, with external measurements, the sample gas has to be drawn out of the
duct in a uniform manner so the sample is representative of the gas stream.
To increase detection coverage, several sampling system designs rely on placing two or
more probes in close proximity. If little care is given to establish the appropriate
number and size of holes, the aspirator may not draw sample air efficiently. In addition,
if the holes face the incoming airflow, these probes are prone to clogging. Adding
sinters in the holes only exacerbates the
problem. Dirty sinters reduce the flow of air into
the sampling system, forcing operators to clean
the sinters regularly or replace them. Another
method is to draw a single sample from a duct
at one point (Figure 6). While this approach is
simple to install and maintain, it often does not
deliver a sample representative of the gases
flowing through the duct.
Multi-probe and single-probe sampling Figure 6: Using a single point of measurement
methods often use catalytic bead, point infrared will usually not deliver an accurate picture of the
and electrochemical sensors, but may be gas stream.

unsuitable for the airflow regime. These sensors may be affected by high
temperatures, prone to drift and have a short life span. False alarms are common, and
in the instance of catalytic bead and electrochemical sensors, the system is not
fail-safe.
An aspirator is an instrument air-driven sampling mechanism, and it addresses the
issues faced by other sampling systems by simultaneously drawing samples across the
entire width of the duct. This ensures all components are captured and the samples are
mixed by the aspirator when the sample is drawn to maintain proper proportions with
respect to their true distribution within the duct.
An aspirator can work with any type of external instrument, so it is not limited to
specific applications. It can be used to measure many types of gases or contaminants,
resulting in improved safety, operations, and regulatory compliance. Typical target
gases detected by aspirator-based systems are hydrocarbons, hydrogen, hydrogen
sulfide, and smoke.
The most common problem with aspirators is debris from the gas stream getting
drawn into the sampling tubes. This can restrict airflow, clog tubing and filters,
requiring them to be frequently cleaned or replaced. Some aspirators contain controls

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Improving Safety by Analyzing Gas Streams in Ducts White Paper

that recognize when there is a clog or

significant pressure change (Figure 7). If the
sample is very humid, water traps are
required, and they must be emptied on a
regular basis. Another issue is loss of
pressure due to leaks in the pipework, but
this can be negated with flow rate
monitoring accessories to detect and fix this
problem.
To address these issues, it is critical to select Figure 7: The aspirator module controls air flows to and
the right aspirator as there are significant from the duct probe and can recognize when flows are
differences among products offered by disrupted by a clog or major pressure change.

different vendors.

Selecting the right aspirator

As compared to other sampling systems, Emerson aspirators simplify plumbing
significantly, so the system is easier to install and maintain. These aspirators use a
self-compensating duct probe (SCDP), with its compact form factor (Figure 8) and
mechanical simplicity easing installation and minimizing maintenance issues. Its small
size reduces the required amount of tubing and, as a result, reduces the number of
tubing connections and flanges, which decreases the number of potential leak sources.

Figure 8: Emerson’s SCDP captures air samples from multiple inlets spaced across the flow profile. This avoids
inaccuracies due to poorly mixed streams or stratified flow. Design also reduces the potential ingestion of dust
and debris into the aspirator system’s piping.

A typical configuration is to locate three probes in each ventilation exhaust with the
system configured to produce an alarm when two-out-of-three channels detect a
dangerous concentration of gas (Figure 8).
An SCDP can operate with a wide range of gas flow rates in the duct. Relatively quick
response time is typical, and it has a mechanism for probe maintenance and calibration
without disassembly or removal.
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Improving Safety by Analyzing Gas Streams in Ducts White Paper

Emerson aspirators feature failsafe operation and have fault indications in the unlikely
event of reduced or reversed airflow. They aspirate sample air from the duct into the
sensor, which is typically vented to the atmosphere after measurement.
Gas sampling and measurement are part of a wide variety of applications and
industries. The following are four examples to illustrate challenges and solutions
offered by Emerson gas and smoke aspirator systems.

Application Examples
Gas Turbines: Natural gas leaks are a potential hazard in gas turbine installations within
the power generation industry. If ignited, the gas could lead to fires, detonations,
destruction of the turbine, and interruption to power generation operations. To
mitigate the risk of these hazards, electrical power generation companies and turbine
manufacturers install gas detection equipment to monitor the ventilated air in gas
turbine enclosures and exhaust vents. According to the Health and Safety Executive
(HSE), the best location for gas detection is in the ventilation outlet because all
potential gas leaks collect in this area.1
Emerson SCDPs can be inserted into the ventilation exhaust outlets to draw air samples
continuously, operating reliably and safely even with the high heat and flow rates
involved. This sample is then transported to a remotely placed combustible gas
detector.
Additionally, there are other monitoring applications related to gas turbine facilities
where SCDPs combined with instruments can improve safety (Figure 9).

Figure 9: Gas turbines need gas sensors monitoring a variety of locations. Placement of self
compensating duct probes and gas and smoke aspirator is shown.

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Improving Safety by Analyzing Gas Streams in Ducts White Paper

 The full enclosure around the turbine should be monitored for natural gas leaking
from the fuel supply, which can accumulate until it reaches flammable or explosive
levels. Air circulates through the enclosure to help cool it, and it is possible to place
SCDPs in the ventilation outlet. The probes should be located downstream to
ensure adequate mixing within the duct.
 In certain turbine packages, the generator operates in a hydrogen atmosphere to
improve performance. This hydrogen must be kept at too high a concentration to
be combustible or it presents a major safety hazard. Leaking hydrogen is a serious
safety concern, so areas surrounding the enclosure can be monitored using a gas
and smoke aspirator system to capture representative samples.
Wastewater Treatment Plants: The second-largest output stream from a wastewater
treatment plant after water is sludge — all the solid material not consumed by the bugs
during the digestion process.
Sludge and water are separated
using a filter press or similar
equipment, and then sent to a
landfill or burned. To reduce the
sludge weight, filtered sludge is
usually heated (Figure 10) to drive
out more water than is possible by
conventional filtration.
Naturally, the content of sludge
varies widely and can contain all Figure 10: Heating sludge to reduce its water content can create corrosive steam
mixed with hydrogen sulfide, which needs to be measured and treated before
manner of chemical components release to atmosphere.
in differing proportions. The
steam driven off the heater normally does not carry heavy metals, but it can carry other
gaseous pollutants, including hydrogen sulfide. Environmental regulations normally
require that such substances be measured and abated if beyond allowable thresholds.
Hydrogen sulfide is not difficult to detect and measure using conventional instruments,
but in this case the air stream in the duct is effectively hot, acidic steam. An in situ
instrument’s sensor will be subjected to this hostile environment, which will cause
corrosion, inaccurate readings, and premature failure. Using an external instrument
with air samples provided by an SCDP aspirator, it is possible to capture an accurate
picture of the air content after dropping out the moisture and drying the sample.
Quantifying the hydrogen sulfide measurement allows adjustments to be made for its
reduction and better control of temperature. This helps satisfy regulatory
requirements, and extends equipment life by reducing the temperature and
corrosiveness of the gas. Using this type of system, it is also possible to put the
instrument in an area some distance from the source to improve air quality for
technicians when maintenance is required.
Printing Plants: Many large web and sheet-fed printing presses are outfitted with
coating units to put clear coatings on printed pieces in selected areas or overall (Figure

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Improving Safety by Analyzing Gas Streams in Ducts White Paper

11). To maintain press speed for maximum

production, these coatings are often
formulated to cure almost instantly by
exposure to intense ultraviolet (UV) or
infrared (IR) radiation. On very high-speed
presses, drying ovens may be used as well to
reduce the setting time of conventional
inks. This allows the printed sheets to be
handled more quickly when going on to
secondary operations such as trimming and
binding.
To avoid heat build-up in these drying Figure 11: Forced curing of inks and coatings to facilitate higher
press speeds can create exhaust streams carrying potentially
stages, most installations have large toxic effluents, including hydrogen sulfide. These streams should
exhaust systems to draw cool air through
the press, which is then sent to atmosphere. However, some inks and coatings are toxic
in their liquid state and may outgas hazardous substances, such as hydrogen sulfide, in
the curing phase. Some coatings are aqueous, adding humidity to the gas stream.
Mounting an SCDP in the exhaust duct can capture an effective cross section of the
flow, which is then dried, if required, and sent to an external instrument for analysis.
Getting an accurate picture of the gas distribution is critical because the coatings or
heavy ink coverage are not always in the same places on a large form, or smaller sheets
may be run through the press. Sources of the gases being monitored may be
concentrated in specific areas, so it is important to use an aspirator rather than a point
collection source. If aqueous coatings are involved, the gas may need to be dried first
due to increased humidity.
LNG or LPG Tankers: Fire and explosions are a potential hazard when transporting
liquified natural gas (LNG) or liquid
petroleum gas (LPG) in tanker ships. These
hazards are likely to occur when flammable
gases, vapors, and liquids are released
from a controlled environment to areas
where there might be an ignition source.
Mass global transport of these fuels is
carried out in ships fitted with tanks of
different designs and arrangements, from
integral tanks, which form a primary
structural part of the ship, to independent
tanks, which are self-supporting (Figure
12). Figure 12: Fixed gas detection sample systems are vital safety
devices in LNG and LPG tankers.
By design, independent tanks do not
occupy the full space of the hull. Rather, space is provided to allow expansion and
contraction of the tank structure due to changes in ambient temperature. In the case
of spherical tanks, a space beneath the structure is used to hold drip trays. Thus, any
leakage in the tank results in the flammable liquid collecting in pans. To detect the loss
of containment, the hold space is filled with air or an inert gas such as nitrogen, and gas

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Improving Safety by Analyzing Gas Streams in Ducts White Paper

detectors are used to detect vapors from the spill. The scheme is effective as the in situ
detectors provide early warning of leaks and spills.
In spite of the merits of placing devices near potential leak sources, the use of fixed gas
detectors in interstitial void spaces is not without its limitations. Such spaces are
difficult to access, and safety regulations may require operators to follow confined
space entry protocols. If inert gas is used to blanket the space, the gas must be
evacuated before workers are allowed into the space to perform service. Therefore,
piped sampling systems are often considered a superior method for protecting tanks
from gas hazards.
LNG tankers have successfully used these systems for many years, with duty holders
citing reduced maintenance costs and risk to personnel as drivers for the change. In
many instances, recommended practices and standards have spurred the wider use of
sampling systems. Consider the International Convention for the Safety of Life at Sea
(SOLAS). According to SOLAS regulation II-2/4 section 5.7.2.2, “due consideration
should be given to the use [of portable gas detectors] in combination with fixed gas
sampling systems” in tankers with double-hull and bottom-spaces.
Emerson’s external sampling systems are well suited for monitoring for vapor releases
in hold spaces. Unlike traditional systems that sample air from multiple points one at a
time, Emerson’s aspirators sample continuously. Response speed is effectively
increased because the design eliminates intervals between sampling, some of which
can be several minutes depending on the length of piping and the number of sampled
points.
Emerson aspirator systems are designed with diagnostics for low flow or blockage of
sampling lines, a key feature to alert the operator when the sample gas no longer
reaches the detectors. Additionally, low flow failures are revealed if flow from house air
decreases below a threshold. Another important feature of Emerson’s aspirator system
is the low number of compression fittings. Fewer fittings not only results in fewer
potential leak sources but also reduce the maintenance
required on the system. Additionally, Emerson aspirators
can be tested and calibrated online.
By contrast, most sampling systems have fittings to
disconnect gas detectors for performing bump tests and
calibrations, a process that takes time and has the
potential for introducing dust, debris, inhibitors, and
other substances that may not be present in the target
zone.
Modularity is another advantage with Emerson sampling
systems. Because LNG or LPG tankers have several storage
tanks, a single vessel may have several sampling cabinets Figure 13: Single channel Emerson gas
for each tank (Figure 13). A modular design facilitates and smoke aspirator system with infrared
hydrocarbon gas detector.
maintenance of the installed product base and reduces the
diversity of spare parts that must be kept in inventory. Modular designs can be
modified or replaced without changing anything else in the cabinets, and the
replacement and installation of new components can be done quickly and easily. For
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Improving Safety by Analyzing Gas Streams in Ducts White Paper

thin crews under rotation, the modularity of Emerson aspirator systems means shorter
learning curves for technicians to become familiar with the systems.
In short, fixed gas detection sample systems play a valuable role for ensuring vessel
safety. They monitor void spaces and inter-barrier spaces around independent cargo
tanks and can also be used to monitor ballast tanks and bulkheads. The sampling
regime ensures gas detectors are within ready access for service, and downtime is
minimized along with the risk to maintenance personnel.

Summary - a comprehensive approach

In addition to the specific applications described above, aspirator-based systems can
be designed to detect smoke, hydrogen sulfide, carbon monoxide, carbon dioxide and
many other components and conditions in a wide variety of applications.
Gas sample analysis in these and other applications is necessary for three main reasons:
 Ensure safety, such as detecting fuel gas leakage
 Aid in regulatory compliance
 Monitor pollutants, such as hydrogen sulfide from a combustion or drying process
Performing these functions reliably, positively and accurately depends on having the
right instrument, but first upon capturing a truly representative sample. Inserting an
Emerson SCDP into the gas stream results in a sample being drawn from across the full
cross section of the flow profile, representing the actual gas composition.

1 “Control of safety risks at gas turbines used for power generation.” Guidance Note PM84; The Health and Safety Executive, 2003.

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 White Paper

For more information about Emerson gas and smoke aspirator systems, see
www.emerson.com/RosemountAspirator

For more information about Emerson self compensating duct probes, see
www.emerson.com/RosemountSCDP

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