Gas Detection Systems

Sensor Operating Theory

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 Gas/Vapor Hazards-

• Flammable/Combustible
• Toxic
• Oxygen-deficiency
• Oxygen-enrichment

2
Gas Detection Objectives

• Measure gas before hazardous

concentration is present
• Provide outputs for Emergency
Action
• Suitable for extreme
environments (arctic, tropic, etc)
• Complement to Flame Detection
equipment
• Cost-effective protection

3
Det-Tronics Gas Sensing Technologies

• Combustibles: Catalytic and Infrared

• Hydrogen Sulfide: Electrochemical & MOS
• Oxygen: Electrochemical
• Carbon Monoxide: Electrochemical
• Chlorine: Electrochemical
• Sulfur Dioxide: Electrochemical
• Nitrogen Dioxide: Electrochemical

4
Key Gas Detection Definitions

• Measurement range: gas concentration at full

scale sensor output
• Unit of Measurement: %LEL, PPM, or %volume
• Flashpoint: minimum temperature of
liquid where enough vapor is
given off to sustain a
fire or explosion
• Vapor Density: tendency of a pure gas of vapor to
rise or sink in clean air
• Calibration: process of matching transmitter
signal to sensor measurement

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 Catalytic Sensor Operation

• Contact-based
• Destructive measurement
• Traditional method
• Only option for hydrogen gas
detection
DET-TRONICS
• Used w/ transmitter module to
ALARM
provide 4-20 ma signal output
INCREASE SETUP DECREASE

ACCEPT
• Typical life of 3-6 years
CAL/RESET

• 2 year mfgr warranty

6
Catalytic Sensor Operation

• Active Element - Hot wire resistor

coated with catalytic material
• Reference Element - Same as
active but without catalyst
• Catalytic Oxidation of flammable
gas generates heat & changes
resistance of Active Element
• Explosion is prevented by Flame
Arrestor
Flammable
gas • Constant E or I power source
required
• Must calibrate on start-up &
routinely for accuracy

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Catalytic Sensor Operation

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Combustible Gases-Lower & Upper Limits*

*No differentiation between the terms “Explosive” and “Flammable” as applied to the lower
and upper limits of flammability

Clean Air

Too lean for ignition Too rich for ignition

50%
Combustibles

Lower Upper
Typical Combustible
Gas Detector Range
Explosive Explosive
of Measurement Limit (LEL) Limit (UEL)

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Flammable Limits & Volumetric Equivalents

Gas Type L.E.L. U.E.L.

Methane 5% 15%
Propane 2.1% 9.5%
Hydrogen 4.0% 75%
Hexane 1.1% 7.5%

Methane Gas: 100% LEL= 5% by volume in air

75% = 3.75 “
50% = 2.5% “
25% = 1.25% “
10% = .50% “

10
Volumetric Equivalents

1.0% by Volume = 10,000 ppm = 10,000,000 ppb

Catalytic Sensor Operation

• Stainless sinter provides ex-proof design

• Barrier prevents thermal interaction
• Unsuitable for low oxygen applications
(<10% O2)
• Can be poisoned by external airborne
substances
• Possible ambiguous reading above 100%
LEL
• Always install w/ sinter pointing
downwards

12
Catalytic Gas Sensor Poisons/Inhibitors

• Poisons affect catalytic sensor response & longevity

• Erosion, impervious covering, or plugging active sites
• Impact depends on poison type, level, time of exposure
• Known catalytic sensor poisons:
• silicone oils, greases, resins (RTV adhesive)
• halogens (halon, chlorine, fluorine, bromine, freon)
• phosphate esters
• tetraethyl lead
• trichlorobenzene
• acid and pvc vapors
• other corrosive materials

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 Background Combustible Gases

• Background combustible gases common in oil/gas

refineries and industrial plants
• Zero “drift” (pos. and neg.) is common symptom
• Affects catalytic sensor service life
• Non-destructive measurement technique (IR) may be
recommended

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 Catalytic Sensor Limitations

FAIL TO DANGER
•Poisoning of Catalyst
•Plugging of Flame Arrestor
•Read Low @ High Gas Levels
•Frequent Calibration
•Service Life - Variable
(Months)
 Drivers for Optical Technology

• Piper Alpha - 167 Dead, $1,000,000,000 Loss

• Flixborough - 28 Dead, $180,000,000 Loss

Drivers for Optical Technology

• Safety Driven Design Requirements

• FAIL SAFE
• No Unrevealed Sources of Failure
• HIGH AVAILABILITY
• Long Service Life
• Low and Easy Maintenance

Requirements are met by

Properly Designed Optical Gas Detection Devices
(not all IR detector designs are equal)
Infrared Combustible Detectors
reference
absorption band

• Principal of Operation active absorption band

Methane
• Gases are Transparent to
Visible Light BUT...
• Gases are Strongly
Opaque to Infrared Light at
Some Wavelengths

Propane
 Non-Dispersive IR Absorption Theory
reference
absorption band active absorption band

• IR absorption “fingerprints”
vary by molecular structure
• Beer-Lambert law defines the
absorption physics

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Point Infrared Detector

• Principle of Operation

IR T ransp are nt W ind ow s

O ptica l B ea m splitte r M easurem ent
Signal D etector

Flammable
hydrocarbon
IR Source
gas G as
Perm eable O ptica l F ilters
C ell

R eference
Signal D etector M icroprocessor
and
Electronics

Gas
Concentration
(LEL)
Fail-Safe Operation

A ctive R eference A ctive R eference

Clean
Air Failed
Sensor

IR S ignal Level IR S ignal Level

A ctive R eference A ctive R eference

Hydrocarbon
Failed
G as
IR-Source

IR S ignal Level IR S ignal Level

A ctive R eference
Dirty
O ptics
and
Clean
Failed M icroprocessor = 0 m A
Air
IR S ignal Level
Open Path IR Gas Detector

• Instrumental Layout

10 - 60 m
Optical Beamsplitter

Measurement
Signal Detector
Flammable
hydrocarbon
IR Source gas
Optical Filters

Microprocessor
and
Electronics
Reference
Signal Detector

Gas
Concentration
(LEL)
IR Hydrocarbon Gas Detectors

• Ratio is related to gas concentration (B-L)

• Not suitable for hydrogen (H2) detection
• Transmittance vs. concentration is non-linear
• Algorithms required to linearize signal output

23
Electrochemical Toxic Sensor Theory

• Specific to toxic gas type (H2S, CO, SO2, NO2, CL2 )

• Consists of sensing(working), reference, and counter electrodes
• Vapor diffusion into capillary results in oxidation/ion reduction
• The signal (current) from the working electrode is converted to a voltage by
operational amplifier
• Voltage signal change is converted to 4-20 ma current signal
• Not intended for applications with high levels of target gas, or flues, stacks, or
scrubbers
Capillary Entrance

O-ring

Sensing Electrode
Membrane
Reference Electrode

Electrolytic fluid Counter Electrode

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Electrochemical Toxic Sensor Operation

• All provide 4-20 ma signal output

• 0-100 ppm range typical
• Carbon monoxide ranges: 0-100, 0-
500, or 0-1000 ppm- must specify
• Nitrogen dioxide range: 0-20 ppm
• Hydrophobic filter provides humidity
protection
• >5% by volume O2 required
• All designed to meet X-proof req.
except CL2, SO2 sensors (I.S.
barrier required)
• All designed for calibration by a
transmitter, controller or external
control system.

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Electrochemical Oxygen Sensor Theory

• Specific to oxygen concentration measurement

• 0-25% by volume measurement range
• Linear 4-20 ma signal
• 21% oxygen concentration = 17.4 ma signal output in normal air
• Ion reduction oxidizes sensing anode
• Not intended for flue stacks or scrubbers

Load Resistor

Anode Electrolyte Cathode Capillary Entrance

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Electrochemical Oxygen Sensor

• Designed for use with U9500C

Infiniti transmitter or R8471C
controller
• Use clean bottled air (20.9%
O2) as Span Calibration gas
• Zero level calibration set using
“zero switch” on sensing cell

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Traditional Sensor Calibration

• Matching transmitter output to raw sensor signal in

clean air (zero) & mid-scale (span) conditions
• Manual or Automatic depending upon transmitter
type
• Adjustments necessary if drifting has occurred
• Requires compressed, accurate calibration gases
• Always required @ start-up & after sensor
replacement
• Every 30-90 days thereafter typical

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Gas Detector Calibration Requirements

• Catalytic Sensors: Field Calibration required for accuracy

• DEC IR Detectors: Routine calibration not required; Factory
calibrated for methane only
• Electrochemical Sensors: Field Calibration required for accuracy
• DEC Open Path IR System: Routine calibration not required; Factory
calibrated for methane only

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Sensor Calibration-K series

• Always apply clean air if

background gases present
• Set Zero level
• Apply Calibration (span) gas
• Allow to stabilize
• Set Span level
• Check & record sensor sens
• Remove gas
• Remove cal meter after
reading drops to < 5% LEL

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Gas Detector Design/Performance Standards

• Gas Detector Approval Agencies:

• Factory Mutual
• Canadian Standards Association
• CENELEC
• IEC
• others
• Other bodies providing recommendations:
• Instrument Society of America
• National Fire Protection Association
• Industrial Risk Insurers

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Develop Your Expertise

• NFPA Handbook #325M Fire Hazard Properties of Flammable Liquids, Gases, and
Volatile Solids (1,300 flammable substances)
• INSTRUMENT SOCIETY OF AMERICA (ISA) Standards-
• S12.12 - Nonincendive Electronical Equipment for Use in Class I and II, Division 2
and Class III, Divisions 1 and 2 Hazardous (Classified) Locations
• S12.13 - Performance Requirements, Combustible Gas Detectors, Part I
• RP12.13 - Installation, Operation, and Maintenance of Combustible Gas Detection
Instruments, Part II
• S12.15 - Installation, Operation and Maintenance of Hydrogen Sulfide Detection
Instruments, Part I
• RP12.15 - Installation, Operation and Maintenance of Hydrogen Sulfide Detection
Instruments

• Educate your customer on how to install, operate, & maintain their gas
system “by the book”