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Upstream
Midstream
Downstream
Oil & Gas 2
Oil & Gas 2
Oil & Gas 2
Clean Water
Waste Water
Collection and storage
Screening
Clarification
Sedimentation
Filtration
Final treatment
Waste generation
Pumping stations
Screening
Primary treatment
Secondary treatment
Final treatment
Sludge treatment
Power generation
Pellet & Sinter Plants
Coke Plant
Blast Furnace
Power Station
Electric Arc Furnace
Continuous Casting
Forming or Secondary Processing
Stalk Removal and Crush
Fermentation
Aging
Clarification, Filtration & Bottling
Delivery & Dispensing
Bottling, Canning & Casking
Separation & Cooling
Fermentation, Conditioning & Cooling
Milling, Mash, Lauter & Brew
Port-Side Support
Port-Side Support
Confined (Enclosed) Space Entry (CSE)
Confined (Enclosed) Space Testing
Inert Space Monitoring
Confined (Enclosed) Space Entry (CSE)
Confined (Enclosed) Space Testing
Inert Space Monitoring
Confined (Enclosed) Space Entry (CSE)
Confined (Enclosed) Space Testing
Inert Space Monitoring
Confined (Enclosed) Space Entry (CSE)
Confined (Enclosed) Space Testing
Confined (Enclosed) Space Entry (CSE)
Confined (Enclosed) Space Testing
Marine
Pressure Management
Local Storage
Low-Pressure/Second Stage Distribution
Above Ground Pipelines
CNG Filling Station
Oil & Gas
The oil and gas industry is a dangerous workplace, and management of hazards a key focus. For the operator, maintaining a high level of plant safety is a critical concern. The most obvious and significant threat is the leakage and combustion of explosive gas. With hazardous gases ever present during production and processing operations, operators are constantly faced with the risk of flammable and toxic gas release and exposure.
Every site is different, and Crowcon employs its specialist gas detection knowledge to provide fixed systems that ensure the best protection suited to each individual site. Working closely with partners to understand the exact requirements is pivotal to our approach. Only in this way can we ensure our control panels and devices integrate efficiently into process control and safety shutdown systems.
Upstream
Process Overview
The upstream sector includes exploration and drilling for potential oil and gas fields, followed by the recovery and production of crude oil and natural gas if it is viable.
Gas hazards in the upstream sector are compounded by the very harshest of environments providing challenges for the reliable detection of harmful gases. Enhanced oil recovery (EOR) technologies and unconventional methods are allowing access to new geographic areas, as well as improving the level of recoverable resources within known reservoirs.
Gas Detection
Fixed and portable gas detectors are required to protect plant and personnel from the risks of flammable gas releases (commonly methane) as well as high levels of hydrogen sulphide particularly from sour wells. Oxygen depletion, sulphur dioxide and volatile organic compounds (VOC’s) are also among the most common gas risks.
Solutions
Gas-Pro IR
This latest offering detects methane, pentane or propane using infrared IR sensor technology
Read More
Midstream
Process Overview
The main components of the midstream process are transportation and storage. Raw products are held in storage areas until ready for the next process or to be transported to a refinery.
Maintaining the integrity of storage and transportation vessels as well as protecting personnel during cleaning, purging and filling activities are a constant challenge within the midstream sector.
Gas Detection
Fixed monitoring of flammable gases situated close to pressure relief devices, filling and emptying areas deliver early warning of localised leaks. Multigas portable monitors maintain personal safety especially during confined space work as well as supporting hot work permit area testing.
Infrared technology supports purging with the ability to operate in inert atmospheres, and delivers reliable detection in areas where pellistor type detectors would fail due to poisoning or volume level exposure.
Portable laser methane detection allows leak location at distance for hard to reach areas, reducing the need for personnel to enter potentially dangerous environments or situations while performing routine or investigative leak monitoring.
Solutions
Gas-Pro IR
This latest offering detects methane, pentane or propane using infrared IR sensor technology
Read MoreDownstream
Process Overview
The Downstream sector refers to the refining and processing of raw natural gas and crude oil, and subsequently distribution and sale of the products derived from this. Such products can include jet fuel, diesel fuel, asphalt and petroleum coke.
Gas Detection
The desire to reduce energy consumption, increasing operational efficiency, has driven device manufacturers to innovate both detection principals and the way in which power is used. Detectors employ state-of-the-art technologies to deliver industry leading power consumption per device.
The volume of personnel on plant and high number of toxic and flammable gases used and manufactured increase the potential hazards. Some risks can be mitigated by ensuring rugged and reliable portable monitors are used, that are well suited to individual on-site requirements. Fleet management tools such as bump test stations deliver exception reporting to track site compliance and calibration status.
The ongoing demand to reduce facility down-time whilst ensuring safety, especially during shutdown and turnaround operations, ensures that gas detection manufacturers must deliver solutions offering ease of use, simple training, reduced maintenance times with local service and support.
Solutions
Water
Frequently regarded as a simple commodity, water is a vital element of day-to-day life, both for personal health and to industrial and commercial users. Whether the facility is focused on cleaning water for drinking or treating effluent, Crowcon is proud to have provided a wide variety of water industry users with gas detection equipment; keeping workers safe around the world.
Gas Detectors should be suited to the specific environment in which they are needed to operate. In the extreme, the water industry is a wet and dirty environment with multiple toxic and flammable gas hazards as well as the risk of oxygen depletion.
Clean Water
Process Overview
The clean water process is the treatment of water prior to general distribution, making it suitable for drinking. This water usually starts as ground or surface water:
- Ground Water: Water taken from below ground sources (e.g. aquifers and springs). This water tends to be relatively clean due to natural processes (chalk beds, natural filtration) and therefore needs only minimal cleaning
- Surface Water: Water taken from above ground sources (e.g. rivers and reservoirs). Water is open to the environment and therefore needs multiple treatment steps.
Gas Detection
The most common gas hazards within the clean water process are from oxygen depletion and the potential for exposure to disinfectant gases such as chlorine, ammonia and ozone.
Waste Water
Process Overview
The waste water process takes multiple forms of liquid waste and changes it into an effluent that can be returned to the water cycle for re-use. Waste water is produced by humans and includes washing water, faeces, urine, laundry waste and processed industry output as well as road and rain water run-off which can also include oils, grease & fuel. The waste water process is commonly referred to as the dirty water process.
Gas Detection
Recognising the harsh environments and multiple applications within this industry, Crowcon has worked with the waste water industry for over 30 years; applying advanced technologies to ensure optimum solutions, focused on improving safety both on and off-site. The very number and volume of toxic and flammable gases present in the waste water environment necessitate the use of fixed and portable gas detection.
Collection and storage
Process Overview
Water is gathered from surface sources and stored in open reservoirs, or below-ground basins. Reservoirs allow blending of newly collected water with existing levels therefore diluting incoming contaminants. Water is held to allow some water quality improvements including debris settlement, with sunlight breaking down organic material and bacterial reduction.
The water is then pumped to treatment facilities.
Gas Detection
The pipelines used to transport the water require regular cleaning and safety checks, during these operations portable multigas monitors are used to ensure the safety of the workforce. Pre-entry checks should be completed prior to entering any confined space and commonly O2, CO, H2S and CH4 are monitored. By their very nature, confined spaces are small in size so portable monitors must be compact and unobtrusive to the user, while being able to withstand the wet and dirty environment in which they must perform. Early and clear indication of any increase in gas monitored (or decrease for oxygen) is paramount wit loud and bright alarms raising the alarm to the user.
Solutions
Screening
Process Overview
Screening is used to remove floating objects that may be in the incoming water. This water is often from open reservoirs and commonly includes physical items like branches, leaves and general rubbish (i.e. packaging waste or containers).
Initial screening prevents these objects from causing problems further down the line.
Gas Detection
Should screening areas become clogged with the vary material they are collecting, then cleaning and maintenance activities will be required. Due to the nature of the areas in question, they should be treated as a confined space, thus requiring multigas monitors to keep workers safe. O2, H2S and CH4 are commonly monitored and depending on the specific site other gases may for part of the overall requirement
Solutions
Clarification
Process Overview
A chemical coagulant is often added to bind together suspended material. This is also called 'flocculation'. This makes particles larger and therefore easier to remove prior to further processing. The 'floc' is removed and the water is ready for the next stage.
Sedimentation
Process Overview
The water then passes through a number of sedimentation vessels, in each stage, heavy sediment settles to the bottom whilst clear water moves on.
- Aeration – Removes or reduces the level of unwanted compounds ( e.g. H2S & CO2) from water, or oxidises dissolved metals to ease removal.
- Carbon and ion-exchange are also methods employed by treatment facilities to remove finer particles.
Gas Detection
Sedimentation vessels are usually naturally ventilated by being placed out in the open. If this is not the case, then fixed and/or portable monitoring for O2, H2S and CH4 as a minimum should contribute to maintaining a safe working environment. Of course if, during the site specific risk assessment, other gases are highlighted in this area of the plant, then fixed and or portable detectors may be required.
Solutions
Xgard Bright
A versatile platform offering flammable and toxic gas detection and oxygen monitoring
Read More
Filtration
Process Overview
Filtration – There are many different forms of filtration
- Granular activated carbon is an advanced system to remove pesticides, organic compounds, unpleasant tastes and odours
- Ozone is injected into the water to breakdown pesticides, organic compounds, ozone also has an anti-bacterial action
- Rapid gravity filtering passes the water through a tank of course sand, this traps unwanted particles
- Slow sand filters passes the water slowly through finer sand, removing smaller particles
Filtration clarifies water, enhancing the effectiveness of the next stage.
Gas Detection
When ozone is used as part of the filtration process it is commonly generated on site. Ozone is a toxic gas at very low levels and therefore requires careful monitoring. Fixed point detection near the site of generation or storage, linked to a localised control system providing audible and visual alarms ensure notification in the event of an escape. Due to the nature of ozone and the way in which it pools at ambient temperatures, best practice also suggests the use of portable detectors monitoring the breathing zone of users entering these areas.
Solutions
Xgard Bright
A versatile platform offering flammable and toxic gas detection and oxygen monitoring
Read MoreFinal treatment
Process Overview
Finally, the water flows into a chemical contact tank, where disinfectant chemicals are added to kill bacteria.
- Chlorine (Cl2) remains the most common form of disinfectant.
- The addition of ammonia (NH3) to chlorine, forms longer lasting chloramines. Chlorine dioxide (ClO2) is principally used as a primary disinfectant for surface waters with odour and taste problems.
- Sodium hypochlorite is effective and reduces storage and handling risks.
- Ozone is a very strong oxidation medium, breaking down odours, bacteria and viruses.
- All chemicals have specific storage requirements commonly set out by local or national regulation.
- Sulphur dioxide can also be used to treat chlorinated wastewater prior to release to 'de-chlorinate' the water.
The water is then pumped close to where it is needed and stored ready for use (e.g. in water towers).
Gas Detection
Storage areas of the chemicals used within the final treatment stage should have robust gas detection systems installed. Even very small escapes of chlorine, ammonia, sulphur dioxide or ozone can be extremely harmful. The behaviour of the gas in question needs to be considered when placing fixed detectors, taking likely escape points and resulting dispersion into account. Remote alarms and the ability to take executive action (e.g. ventilation fan turn on, automatic valve actuation) can be employed should a leak be detected. Portable monitors with the relevant toxic sensor(s) should be used in these areas to ensure worker safety.
Solutions
Xgard Bright
A versatile platform offering flammable and toxic gas detection and oxygen monitoring
Read MoreWaste generation
Process Overview
Waste water is gathered from homes and industry, commonly road run-off and storm drain water is also included. Manholes spaced regularly along distribution pipelines allow inspection, cleaning and maintenance activities. Gravity is often utilised to transport the waste along underground systems.
Gas Detection
During the distribution of waste water, confined spaces are prevalent. H2S flammable and oxygen detection are common configurations (with the addition of CO &/or CO2 in some applications) used for CSE. Cleaning and maintenance activities potentially expose workers to toxic and flammable gases as well as oxygen depletion. The use of multigas portable monitors for pre-entry checks and continuous monitoring reduce the risks for workers.
Solutions
Pumping stations
Process Overview
Pump or lift stations, are usually unmanned; designed to handle raw sewage fed from underground gravity distribution pipelines. The waste is fed into, and stored, in an underground pit, commonly known as a wet well. Traditional sewage pumping stations incorporate both a wet and dry well, separated by an internal divide. Pumps are installed below ground level on the base of the dry well with inlets below the water level on pump start. When the sewage level rises to a predetermined point, pumps lift the sewage into a gravity manhole; to the next station.
Gas Detection
As many pump and lift stations are unmanned, both fixed and portable monitoring methods are commonly employed.
Fixed systems with localised control panels offer visible and audible alerts of dangerous gas levels as well as having the capability to drive executive action such as activating ventilation fans. Fixed application focused solutions have the ability to monitor gas levels directly above varying wet well water levels, alerting the workforce to hazards prior to entering the lift station.
Dry wells are underground, confined spaces and require the use of appropriate multigas monitors in-line with local or company confined space entry requirements and/or regulations.
Solutions
Screening
Process Overview
After passing through multiple pumping stations, the wastewater enters the treatment plant. At this point it includes physical items picked up along the way, like wood, rocks and packaging materials. The initial screening process removes this, preventing the objects from causing problems further down the line.
Gas Detection
Should screening areas become clogged, then cleaning and maintenance activities will be required. Due to the nature of the areas in question, they should be treated as a confined space, thus requiring multigas monitors to keep workers safe. O2, H2S and CH4 are commonly monitored and depending on the specific site other gases may for part of the overall requirement.
Solutions
Primary treatment
Process Overview
The wastewater then enters a series of long, parallel concrete tanks, each tank is divided into two sections. The settlement tank allows solid matter to sink, with the top water running over a divide, the water is then shaken up and exposed to air, this causes some of the dissolved gases, such as hydrogen sulphide, to be released from the water. Air is pumped through the water. As organic matter decays it consumes oxygen, aeration replenishes the oxygen ensuring the dissolved gasses continue to be released. Bubbling oxygen through the water also keeps the organic material suspended while it forces 'grit‘ to settle out. This grit is pumped out of the tanks and taken to landfill sites.
Gas Detection
Sedimentation vessels are usually naturally ventilated by being placed out in the open. If this is not the case, then fixed and/or portable monitoring for O2, H2S and CH4 as a minimum should contribute to maintaining a safe working environment. Of course if, during the site specific risk assessment, other gases are highlighted in this area of the plant, then fixed and or portable detectors may be required.
Solutions
Xgard Bright
A versatile platform offering flammable and toxic gas detection and oxygen monitoring
Read MoreSecondary treatment
Process Overview
Secondary treatment facilitates the biological break down and reduction of residual organic matter. Wastewater enters a set of clarifiers where the sludge (the heavy, organic portion of the sewage) settles out of the wastewater and is pumped out of the tanks. Some of the water is removed in a step called thickening and then the sludge is processed in large tanks called digesters (see later section on sludge treatment). As sludge is settling to the bottom of the clarifiers, lighter materials are floating to the surface, this 'scum' includes grease, oils, plastics, and soap. Slow-moving rakes skim the scum off the surface of the wastewater.
Gas Detection
As the biological breakdown process consumes oxygen, it is possible to create oxygen depletion zones within processing areas. As these vessels are usually open to the elements, the use of portable monitors for O2 ensure worker safety. If vessels are enclosed, then fixed detectors are used to ensure a safe working environment.
Solutions
Final treatment
Process Overview
Finally, the wastewater flows into a chemical contact tank, where chemicals (e.g. chlorine) are added to kill bacteria, which could pose a health risk, just as in swimming pools. The chlorine is mostly eliminated as the bacteria are destroyed, but sometimes it must be neutralized by adding other chemicals. This activity protects fish and other marine organisms as the treated water (called effluent) is then discharged to local rivers or the ocean.
Other forms of disinfectant are also used including chloramines, chlorine dioxide, sodium hypochlorite (hypo) and ozone.
Gas Detection
All chemicals have specific storage requirements commonly set out by local or national regulation. Even very small escapes of chlorine, ammonia, sulphur dioxide or ozone can be extremely harmful. Fixed gas detection will be needed to ensure storage areas are monitored, commonly linked to external alerts (sounders & beacons) to ensure workers are notified of any increases in gas level as well as having the capability to drive executive action such as activating ventilation fans. Focus should be placed on the site-specific risk assessment including gas behaviours; for example chlorine is 2.3 times heavier than air and tends to pool, staying close to the ground and can be absorbed by porous materials. Because of this, portable monitors with the capability to monitor specific gases for storage areas.
Solutions
Xgard Bright
A versatile platform offering flammable and toxic gas detection and oxygen monitoring
Read MoreSludge treatment
Process Overview
Sludge is a consequence of sewage treatment, it is the residual organic matter and dead bacteria used in the treatment process or bio-solids removed from the waste water being treated. Sludge is commonly transferred to anaerobic digesters, where it is heated to encourage bacteria which in turn create biogas. There are a large number of constituent gases in the resulting Biogas:
- Methane: 58.5%
- Carbon Dioxide: 40%
- Nitrogen: 1%
- Oxygen: 0.5%
- Hydrogen Sulphide: 3000ppm
- Hydrogen: 40ppm
Gas Detection
While digestion takes place in sealed vessels, the high levels of CH4 and H2S mean that pellistor methane detectors will be ineffective should there be an escape. The use of Infra-Red methane detection is needed in this environment to ensure a safe working environment. Use of fixed and portable monitors in this area of the plant is commonplace.
Solutions
Xgard Bright
A versatile platform offering flammable and toxic gas detection and oxygen monitoring
Read MoreGas-Pro IR
This latest offering detects methane, pentane or propane using infrared IR sensor technology
Read MorePower generation
Process Overview
Water companies have become increasingly involved in generating electricity from sewage sludge as the high level of methane represents a rich source of energy. Some facilities have an on-site power station (combustion engines) used to convert the biogas into electricity. The resultant electricity can be used both for on-site consumption and for sale to the national grid. Alternatively, the biogas is used directly to provide fuel to heat the digesters. The high level of methane in either form represents a rich source of energy.
Gas Detection
The bio-gas generated through the digestion process must be stored and ‘cleaned’ prior to use. This created the need for fixed and portable detection. Regular ‘leak detection’ surveys will take place to ensure the integrity of storage vessels and distribution pipes.
Solutions
Gas-Pro IR
This latest offering detects methane, pentane or propane using infrared IR sensor technology
Read MoreSteel
Regarded by many as providing the backbone to modern society, the steel industry is one which continues to evolve.
There are many different processes employed in making and forming steel and each stage generates and uses potentially hazardous gases. Coke ovens, the sinter plant, blast furnaces, forming operations as well as secondary steel and continuous casting use or produce dangerous levels of gases. Due to the large amount of water needed during processing as well as the heavy power requirement, water treatment and power generation facilities are commonly part of steel facilities; these bring further gas hazards depending on the type of fuel or treatment employed.
Whether it is geographic shifts in demand or production, or challenges brought by energy or raw material costs, companies continue to develop their processes and facilities to meet them. Alongside these changes companies have also realised the requirement to minimise downtime due to unplanned maintenance and protect workers from exposure to toxic or flammable gas hazards.
Supporting these initiatives, Crowcon and its network of trained and experienced distributors has provided gas detection equipment to most of the major steel companies around the world.
Pellet & Sinter Plants
Process Overview
The pellet process involves fusing iron ore particles into uniform pellets before they are sent to the blast furnace. A rotary kiln running at temperatures of up to 1325°C (2400°F) is used to form the pellets combining the iron ore particles with bentonite (a binder), limestone, anthracite and coke may also be added to improve the final properties of the pellets.
The sinter process involves fusing iron ore particles into ‘cakes’ before they are sent to the blast furnace. A conveyor-furnace heats iron ore with lime and coke to form the ‘cake’ that is then broken into pieces.
Gas Detection
Pellet and Sinter plants release sulphur dioxide, carbon monoxide and carbon dioxide during processing and the environment is dusty. Kilns or furnaces are often gas fired, introducing the need for flammable gas detection. Gas hazards also include unburned gas from burner flame-outs and oxygen depletion due to combustion.
The grainy ferrous dust generated throughout the process requires removable filters that can be replaced or cleaned on a regular basis to ensure gas can travel to the sensor.
Solutions
Coke Plant
Process Overview
Coal is transformed into coke through an intense heating process, during which a mixture of high levels of the toxic and/or flammable gases carbon monoxide and hydrogen is produced. This gas mixture is used as fuel in other parts of the plant once other valuable but potentially harmful by-products such as ammonia, naphthalene and benzol have been removed and collected. The coke is cooled and passed to the blast furnace.
Coke production also generates large amounts of wastewater due to the amount required during quenching. This can contain elements of ammonia, phenols, cyanide, thiocyanate, chloride and sulphide. The cleaning of this waste water takes place at the same facility, and is commonly re-used for processing.
Gas Detection
Gas detection manufacturers that have experience in these environments well know the issues of hydrogen affecting electrochemical carbon monoxide sensors and provide hydrogen filtered sensors as standard to steel facilities.
When considering gas detection in or around the water treatment facility, other toxic gases may be present including ammonia, sulphur dioxide and hydrogen sulphide. Fixed detectors with the capability to monitor gases both in-use and during storage are common in these areas. Portable multigas monitors with the ability to monitor personal exposure over time improve personal safety levels delivering TWA (time weighted average) levels.
Solutions
Blast Furnace
Process Overview
Using coke as a fuel, very high temperatures are obtained by forcing hot air into a blast furnace. As well as iron ore and coke, limestone is added to help separate impurities called gangule from the molten iron by combining with them to form a liquid slag that can be skimmed from its surface. A blast furnace produces a great deal of hot, dusty, toxic and flammable gas consisting of carbon monoxide with some hydrogen - the dust is removed and the clean gas stored for re-use, or transported directly to the on-site power plant.
Iron is converted into steel by removing impurities, most commonly via the Basic Oxygen Steel (BOS) process. Molten iron (‘hot metal’) is poured into an egg shaped steelmaking converter mounted on pivots so that it can be rotated. A long water-cooled ‘lance’ is lowered into the converter and pure oxygen blown through it. The oxygen combines with carbon and other elements eliminating some impurities while added lime reacts with others to form a slag. The carbon leaves the converter as carbon monoxide gas, which is cleaned and reused as a fuel or burned off. Nitrogen and argon may then be added for further refining before the steel is passed for secondary steel making or continuous casting.
Gas Detection
Gas hazards include those associated with enriched oxygen, carbon monoxide and the oxygen depleting effects of nitrogen and argon. Gas detection manufacturers that have experience in these environments well know the issues of hydrogen affecting electrochemical carbon monoxide sensors and provide hydrogen filtered sensors as standard to steel facilities.
Oxygen monitors that provide warning of both deficient and enriched environments as well as use of infra-red technology to detect hydrocarbon gases in inert atmospheres all contribute to increasing safety. The combination of both fixed and portable monitoring covering flammable, toxic and oxygen detection can provide site-wide risk specific warnings.
Solutions
Power Station
Process Overview
The steel making process demands high amounts of energy. This energy provides power and heat for the steel plant operations as well as being a raw material required for the production of coke. Due to the demands for energy, it is common for steel mills to have on-site power plants, important for maintaining continuity of supply as well as recycling the important off-gases from the coke plant and blast furnace. These plants are responsible for receiving and storing the off-gas as well as performing the cleaning processes to remove impurities before it can be used to generate more power.
Gas turbines effectively and efficiently use produce electricity to support the steel plant, improving the economy of the overall pant as well as effectively dealing with the generated off-gas.
Gas Detection
Flammable detectors are used to monitor the distribution pipes for fuel used by the gas turbines as well as during the cleaning operation. Fixed detectors are also required around storage vessels monitoring for potential leaks.
Inert atmospheres created by the storage and transmission of fuel gases (methane &/or hydrogen) make monitoring of oxygen for personnel working in and around the plant important.
Power Stations use high-voltage switchgear to help protect, control and isolate electrical equipment. These commonly contain SF6 as an insulator. SF6 presents a potential toxic risk as well as having the ability to cause environmental damage should the SF6 leak.
Solutions
Crowcon F-Gas Detector
Can be connected to any control system that accepts an analogue signal
Read MoreElectric Arc Furnace
Process Overview
Electric Arc Furnaces are used to make special quality steels and non-alloy steels and is an effective way of recycling ‘scrap’, the EAF can complete the tap-to-tap process in under an hour.
The EAF also carries out refining operations removing impurities such as phosphorus, silicon, sulphur, manganese, carbon and aluminum from the steel. Dissolved gases are also present during the melt stage including hydrogen and nitrogen. Oxygen is commonly introduced at the end of the meltdown to oxide impurities making them rise into the slag (which is removed).
Gas Detection
Gas detectors with the ability to monitor the oxygen during storage and use improve safety around the processing area. Dependant on the type of scrap used and the grade of steel being produced, toxic gas detection may be required to monitors gases such as carbon monoxide and sulphur dioxide.
Solutions
Continuous Casting
Process Overview
The steel is given one or more extra treatments depending on the grade of steel required. These stages include ladle stirring with argon or nitrogen and vacuum degassing. These processes reduce unwanted gases such as those of sulphur and carbon to very low levels.
The steel is passed to a concast machine where it is fed into water-cooled moulds to solidify. When solid, it is cut into slabs and passed to the hot mill for re-heating to 1,300°. Once re-heated it is rolled into strips or billets. These processes present hazards of oxygen depletion, toxic sulphur or carbon derived gases and flammable risks from potential burner flame-outs.
Gas Detection
Many crawl spaces, service hatches and inspection points are compact, demanding multigas confined space monitors that do not hamper movement yet provide loud and bright indications should gas levels exceed the site-defined alarm levels.
Solutions
Forming or Secondary Processing
Process Overview
The Forming or Secondary Processing plant is responsible for receiving the steel billets from the Steel mill. These processes can take place away from the original steel mill allowing this to take place closer to where the end customer is situated.
The billets are heated in furnaces before they are loaded into the forging die to be re-formed. Billets may be large or small. The billet furnace may be gas-fired or induction-heated. In some cases only the end of a product, such as the end of a rod or tube, is heated and formed. In other cases, the entire billet is heated. The efficiency of the heating process and the consistency of the formed product rely on a well-controlled billet preheat temperature.
Gas Detection
As the billets must be re-heated in order to be formed into the desired product, there is the potential for gases to be generated during the process. These processes present hazards of oxygen depletion, toxic sulphur or carbon derived gases as well as flammable risks from reheat burner flame-outs.
Solutions
Winery & Brewery
Once an archetypal example of manual production, the winery and brewery industries now incorporate sophisticated processes to ensure high quality levels and efficient output.
In some cases traditional approaches have been scaled up or put under more stringent monitoring, whilst in others innovations such as nitrogen-pressurised canning/bottling have been introduced. However, whichever approach has been followed realisation has grown of the associated gas hazards, and the need to protect workers from toxic gas exposure and asphyxiation risks.
Gas hazards within wineries and breweries include carbon dioxide from fermentation, chilling, blanketing and recovery; disinfectants such as ozone and sulphur dioxide for cleaning equipment; argon and nitrogen used as blanketing gases to create inert atmospheres; ammonia from refrigeration equipment; methane from fuel for heating or heavy lifting equipment; carbon monoxide within exhaust gases and hydrogen sulphide which could be present during waste treatment. Wineries and breweries have a high number of confined spaces which demand oxygen monitoring as well as process specific gases.
With over 45 years experience in gas detection and a network of trained distributors and service agents supporting winery and brewery clients around the world, regular users of Crowcon equipment include most of the major brewing groups as well as both large and independent wineries.
Stalk Removal and Crush
Process Overview
Once picked, grapes are sorted and the stalks removed. If this work is not happening at the vineyard, dry ice (solid carbon dioxide) in cryogenic vessels or a snow-horn can be used to control the temperature of the grapes during harvest and transportation. Sulphur dioxide is sometimes used as an anti-oxidant to inhibit yeast or mould growth prior to crushing. Carbon dioxide may be introduced to act as an inert gas layer above the grapes, maintaining freshness.
Gas Detection
Sulphur dioxide and carbon dioxide monitoring should be implemented within the processing area to ensure a safe working atmosphere, especially when initial processing is carried out inside. The use of portable monitors can effectively screen personal exposure levels. Due to the relevant behaviour of these gases, the placement of fixed detectors is an important consideration, to warn workers before they enter an area with dangerous gas levels.
Solutions
Fermentation
Process Overview
The making of red wine differs from making white wine. In the case of red wine, the crushed grapes are fermented with their skins, and then pressed. For white wine, the grapes are pressed after the crush to separate the juice from the skins, the juice is then fermented. This is not however the only difference. Red wine is commonly fermented in ‘open’ vats with the carbon dioxide generated during fermentation acting as its own oxidisation barrier. White wine is fermented in sealed containers to reduce the potential for oxidation.
During fermentation oxygen can be added to improve color stability and aid the fermentation process by helping the yeasts grow. It is very important to maintain the temperature of the mixture to ensure the right rate of fermentation and color extraction; this is achieved with precise heating and ventilation control. Sulphur dioxide can be used to halt fermentation once the correct taste is achieved and nitrogen introduced to bring yeast out of suspension.
Once fermentation is complete the liquid is transferred, often using argon, nitrogen or carbon dioxide to reduce the potential for oxidation. Removal of the skins from vats is one of the most dangerous jobs at a winery; unfortunately lives are lost every year as a result of inadequate precautions.
Gas Detection
Carbon dioxide is a toxic gas, with life threatening effects taking place at as little as 0.5% by volume CO2. OSHA reflects this in the current standard listing 5000ppm (0.5% vol) as an 8 hour TWA concentration. Concentrations greater than 100,000ppm (10% by volume) can kill. Because CO2 is completely odourless and colorless, there may well be no indication of danger until it is too late. Importantly, elevated levels of carbon dioxide can be toxic, even with adequate oxygen for life support.
Vats are considered ‘Confined Spaces’ and workers require adequate training prior to entry. Confined spaces are commonly defined as “a place which is substantially enclosed (though not always entirely), and where serious injury can occur from hazardous substances or conditions within the space or nearby (e.g. lack of oxygen).” Vats are confined spaces for all of the above reasons, with the risk of elevated carbon dioxide levels posing a toxic hazard. Safety procedures must reflect local regulations and commonly a permit should be completed prior to entry.
HVAC systems are commonly powered by natural gas and also use refrigerants for the cooling cycles. Heating systems have the potential to generate carbon monoxide and ammonia is being used more frequently (over CFC’s and HCFC’s) for cooling and refrigeration activities.
Gas storage areas contain high pressure cylinders of argon, nitrogen, oxygen, sulphur dioxide and carbon dioxide as well as housing gas generators for nitrogen. Fixed gas detection is often installed to ensure pressurised cylinders are not leaking, providing early warning of any potential issues to workers.
Solutions
Aging
Process Overview
Wine blanketing introduces an inert gas to reduce the potential for the wine to absorb any dissolved oxygen. The vats or barrels needed for aging the young wine are sterilised prior to use. Ozone is also used in some instances during cleaning as well as sulphur dioxide to ensure the vat or barrel is completely sanitised and inert (no oxygen present). The wine is then pumped using nitrogen, carbon dioxide or argon, into the vessels and then capped. The wine is stored in a temperature controlled climate for 6 months to 3 years.
Gas Detection
Gas storage areas could contain argon, nitrogen, sulphur dioxide and carbon dioxide. Fixed gas detection is often installed to ensure pressurised cylinders are not leaking, so providing early warning of any potential issues to workers. Inert atmospheres contain no oxygen, this presents the risk of asphyxiation within handling and storage areas.
Rigorous hygiene requirements in the industrial environment of a winery can be tough on any product. The Ingress Protection (IP) rating given to a product is therefore of great importance. IP65 offers total protection against dust as well as protection against low pressure jets of water and IP67 offers the added ability to withstand immersion in liquid, including water, wine or beer.
Solutions
Clarification, Filtration & Bottling
Process Overview
Once aged, the wine is clarified and filtered. Clarification removes unwanted suspended particles. Fining involves adding a substance in order to clarify the wine, improving stability and filtration strains out any particles. These activities remove the risk of microbial spoilage and help to make the wine bright and clear.
The final stage in wine production, bottling, can happen at the winery or off-site at large-scale bottling plants. Some wineries use contract bottlers who have mobile bottling facilities that are brought to the winery at bottling time.
Bottles are evacuated and flushed with nitrogen, argon or carbon dioxide prior to filling in order to reduce the amount of contact the wine has with air.
Once bottled, the wine is packaged and stacked onto pallets. Heavy lifting equipment (e.g. forklift trucks) is used to move the pallets either into storage or onto transport for distribution and warehousing.
Gas Detection
Gas storage areas could contain high pressure cylinders of argon, nitrogen, oxygen, sulphur dioxide and carbon dioxide as well as housing gas generators for nitrogen. Fixed gas detection is often installed to ensure pressurised cylinders are not leaking, providing early warning of any potential issues to workers.
Heavy lifting equipment can be fossil fuel powered (compressed natural gas, liquid petroleum gas or diesel) with the potential for exhaust gas build up. Areas with inadequate ventilation should have adequate gas detection to improve worker safety.
Solutions
Delivery & Dispensing
Process Overview
Once the wine is bottled and the beer is packaged, they must be delivered to the outlet. This commonly includes distribution companies, warehousing and in the case of breweries ‘draymen’.
Beer and soft drinks use carbon dioxide or a mix of carbon dioxide and nitrogen as a way of delivering beverage to the ‘tap’. The gases also give beer a longer lasting head and improve the quality and taste.
Gas Detection
Even when the beverage is ready to deliver, the risk of gas-related hazards are still present. Those involved in any activity entering premises that contain compressed gas cylinders could be exposed to increased carbon dioxide levels or depleted oxygen levels (due to high levels of nitrogen).
In some regions cellars may have fixed CO2 detectors &/or O2 depletion detectors in place, a large number still do not recognise the inherent danger involved in using and storing these compressed gases. Employers have a duty of care to their workers, who regularly enter another business to perform their duties (service, maintenance, delivery or sales). Providing portable monitors, capable of monitoring either CO2 or CO2 and O2, can improve the safety of their working environment.
In the era of increasing legislation and the need to demonstrate a high level of workforce protection, inbuilt data and event logging capabilities as well as customer focused asset management reporting can directly help to improve visibility of information and streamline unit maintenance and calibration activities.
Solutions
Bottling, Canning & Casking
Process Overview
The final stage, packaging, can happen at the brewery or off-site at large-scale plants. Finished beer is carefully pumped into bottles or kegs in an oxygen free atmosphere. Bottles are evacuated and flushed with nitrogen, argon or carbon dioxide prior to filling in order to reduce the amount of contact the beer has with air.
Some canned beers use a ‘widget’ which on opening forces nitrogen into the beverage to improve the quality and stability of the head. During canning, the beer is pressurised, adding liquid nitrogen which expands once the can is sealed.
Bottled beer is often cold stored to maintain freshness. Heavy lifting equipment (e.g. forklift trucks) is used to move the pallets either into storage or onto transport for distribution and warehousing.
Gas Detection
Gas storage areas contain high pressure cylinders of argon, nitrogen, oxygen, sulphur dioxide and carbon dioxide as well as housing gas generators for nitrogen. Cleaning gases can also be generated in this area. Fixed gas detection is often installed to ensure pressurised cylinders are not leaking, providing early warning of any potential issues to workers.
Heavy lifting equipment can be fossil fuel powered (compressed natural gas, liquid petroleum gas or diesel) with the potential for exhaust gas build up. Areas with inadequate ventilation should have adequate gas detection to improve worker safety.
Solutions
Separation & Cooling
Process Overview
The hot wart must then be separated; this is done in most industrial breweries with a number of separation tanks including sedimentation, whirlpool or centrifuge. At this point, the wort is still hot and must be cooled before the yeast is added to aid fermentation. Quick cooling maintains the quality of the beer as well as reducing the risk of contamination. A plate heat exchanger is frequently used, warming up water to be used elsewhere in the process as a result. The final cooling stage often involves sub-zero temperatures as well as dissolving oxygen into the liquid to revitalise the natural yeast.
The brewing process uses a large amount of water; volume breweries commonly manage their own water treatment, recycling processed water into the next batch of beer. Water treatment can include using ozone, chlorine, chlorine dioxide or sodium hypochlorite. Water with a high organic content can also be used to generate valuable biogas.
Gas Detection
Ammonia is becoming the coolant of choice within many process industries including brewing. Ammonia is a cost effective and efficient cooling medium. It is however highly toxic at very low levels and combustible at volume levels, so systems should be monitored for leaks and service or maintenance crews protected against toxic exposure.
Ozone, chlorine and chlorine dioxide are all heavier than air, making them amongst the more difficult gases to detect. Use of the Crowcon Environmental Sampling Unit is an effective way to detect within disinfectant stores successfully, while minimising the number of detectors required.
Solutions
Fermentation, Conditioning & Cooling
Process Overview
Fermentation starts as soon as yeast is added to the cooled wart. Here sugars from the malt are metabolised into alcohol and carbon dioxide. Fermentation vessels differ greatly and can be either closed or open depending on the variety of beer being brewed.
In general, ales will use top fermenting yeast and be fermented warm with the temperature being maintained throughout. Lager generally uses bottom fermentation and is fermented cold. The brew cycle is longer than ale differing from as little as 7 days to several months.
As fermentation slows, the beer is cooled to around freezing point to settle out the yeast and unwanted proteins. The fermented beer is then filtered (if required) and cooled.
Gas Detection
Carbon dioxide is a toxic gas, with life threatening effects taking place at as little as 0.5% by volume CO2. OSHA reflects this in the current standard listing 5000ppm (0.5% vol) as an 8 hour TWA concentration. Concentrations greater than 100,000ppm (10% by volume) can kill. Because CO2 is completely odourless and colorless, there may well be no indication of danger until it is too late. Importantly, elevated levels of carbon dioxide can be toxic, even with adequate oxygen for life support.
Vats are considered ‘Confined Spaces’ and workers require adequate training prior to entry. Safety procedures must reflect local regulations and commonly a permit should be completed prior to entry.
HVAC systems are commonly powered by natural gas and also use refrigerants for the cooling cycles. Heating systems have the potential to generate carbon monoxide and ammonia is being used more frequently (over CFC’s and HCFC’s) for cooling and refrigeration activities.
Gas storage areas contain high pressure cylinders of argon, nitrogen, oxygen, sulphur dioxide and carbon dioxide as well as housing gas generators for nitrogen. Fixed gas detection is often installed to ensure pressurised cylinders are not leaking, providing early warning of any potential issues to workers.
Solutions
Milling, Mash, Lauter & Brew
Process Overview
The start point for any beer is malted grain. Depending on the region and the type of beer being brewed this can be barley, wheat or rye. The grain is steeped in water, drained and allowed to germinate, while being held at a constant temperature for close to two days. The temperature the germinated grain is then dried at depends on the required taste of the finished beer. The germination stage captures sugars to ensure successful fermentation. The dried grain is then milled and transferred into the mash mixer.
Within the mash mixer, the ground grain is mixed with water in order for the starch, sugar and enzymes to dissolve. The temperature of the ‘mash’ is raised, and it is mixed to convert the last of the starch to sugar. The mash is then pumped into a lauter tun where the liquid is strained from the grains (lautering). The liquid (now known as ‘wort’) is gathered in the brew kettle and boiled with hops &/or other ingredients to flavour the final brew.
Gas Detection
During storage, grain naturally depletes oxygen levels and causes carbon dioxide levels to increase. Silos and storage barns should have their atmospheres tested prior to worker entry to ensure safety. Silos are defined as confined spaces, and so workers should be trained to enter and wear appropriate portable detectors capable of monitoring TWA levels for toxic gases (for example carbon dioxide) as well delivering instantaneous alarms.
Solutions
Marine
The marine environment is a dangerous one; everyone can appreciate the hazards afforded by high seas in a storm or beneath the waves, such as rocks and coral reefs. Less well recognised, however, are the dangers posed to mariners by the confined spaces of the ship itself, or the hazards presented by the cargo a vessel is carrying or the process being carried out on-board.
To ensure the safety of mariners, gas monitoring equipment is essential. Gas detection equipment requires specific marine environment testing and certification to ensure suitability to the extreme environments in which it must operate. Safety systems are regulated by region and the flag state or the registry of the vessel decides what type and volume of approved equipment the ship has to carry. The European Marine Equipment Directive (MED) approval is internationally recognised. Gas detectors used by mariners onboard a vessel registered in an EU country must hold MED approval and show the wheel mark. Crowcon provides a range of wheel-marked gas detectors, ideal for use on-board ships, to enable compliance with the directive.
The International Convention for the Safety of Life at Sea (SOLAS) is one of the oldest conventions of its kind. The first version was adopted in 1914 following the sinking of the R.M.S. "TITANIC" with the loss of more than 1500 lives. The present version is SOLAS 1974 version which entered into force in 1980. Parts of the Convention apply to every ship, including small pleasure craft.
Chapter 1 provides information on the application and definitions of requirements for the marine industry, specifically detailing the applicability of this requirement by vessel type. In short, vessels that are classified as passenger or cargo ships greater than 500 gross tons and engaged on an international voyage are subject to the new requirement. The regulations, unless expressly provided otherwise, do not apply to:
i. Ships of war and troopships.
ii. Cargo ships of less than 500 gross tons.
iii. Ships not propelled by mechanical means.
iv. Wooden ships of primitive build.
v. Pleasure yachts not engaged in trade.
vi. Fishing vessels.
Amendments are regularly made to the published version of SOLAS and adopted by referenced resolutions. There have been a number of resolutions specific to the use of portable gas detection aboard vessels.
Port-Side Support
Process Overview
The very nature of the marine industry is such that vessels must spend the majority of their time away from port. This influences the way in which port-side services must work. Quick turnaround times for any requirement from delivery of a new anchor to the supply of gas detection must happen within very specific constraints. Availability of supplies is an important consideration and establishing reliable international supply routes is an effective way to minimise delays.
Gas Detection
Vessel Masters need gas detection that is internationally available, reliable, easy and intuitive to use, these things are a given in this industry. Detectors that are easy to calibrate, on-board and offer crew-members the ability to generate reports demonstrating compliance can add benefit. What is often overlooked however is the provision of dedicated, application relevant, training material that can be used even when a vessel is away from port.
Crowcon has credibility within the marine industry, with crews using Crowcon detectors for over 20 years. This experience has lead to the development of Marine specific products, with the ability not only to withstand the harsh and varied environments in which they must operate but also with the support materials needed to ensure crews have the right information and training.
Solutions
Crowcon international network of service agents
Calibration Solutions
Training material
Please contact us for further information
Port-Side Support
Process Overview
The very nature of the marine industry is such that vessels must spend the majority of their time away from port. This influences the way in which port-side services must work. Quick turnaround times for any requirement from delivery of a new anchor to the supply of gas detection must happen within very specific constraints. Availability of supplies is an important consideration and establishing reliable international supply routes is an effective way to minimise delays.
Gas Detection
Vessel Masters need gas detection that is internationally available, reliable, easy and intuitive to use, these things are a given in this industry. Detectors that are easy to calibrate, on-board and offer crew-members the ability to generate reports demonstrating compliance can add benefit. What is often overlooked however is the provision of dedicated, application relevant, training material that can be used even when a vessel is away from port.
Crowcon has credibility within the marine industry, with crews using Crowcon detectors for over 20 years. This experience has lead to the development of Marine specific products, with the ability not only to withstand the harsh and varied environments in which they must operate but also with the support materials needed to ensure crews have the right information and training.
Solutions
Crowcon international network of service agents
Calibration Solutions
Training material
Please contact us for further information
Confined (Enclosed) Space Entry (CSE)
Process Overview
On 1 January 2015, within SOLAS Resolution MSC.350(92), it became mandatory for all crew members with enclosed space entry or rescue responsibilities to participate in an enclosed space entry and rescue drill. These drills are to be held on board the ship at least once every two months.
This regulation states the drill must include:
- checks and use of PPE (Personal Protective Equipment)
- checks and use of communications equipment and procedure
- checks and use of atmosphere measuring devices
- checks and use of rescue equipment
- instruction on first aid and resuscitation
SOLAS Resolution A.1050(27) defines an enclosed space as:
“2.1 Enclosed space means a space which has any of the following characteristics:
1. limited openings for entry and exit;
2. inadequate ventilation; and
3. is not designed for continuous worker occupancy,
and includes, but is not limited to, cargo spaces, double bottoms, fuel tanks, ballast tanks, cargo pump-rooms, cargo compressor rooms, cofferdams, chain lockers, void spaces, duct keels, inter-barrier spaces, boilers, engine crankcases, engine scavenge air receivers, sewage tanks, and adjacent connected spaces. This list is not exhaustive and a list should be produced on a ship-by-ship basis to identify enclosed spaces.”
Gas Detection
Entering a confined (enclosed) space is a dangerous activity. Not only should crew members be trained in the use of portable gas monitors, they should also be able to take part in rescue drills as dictated in the SOLAS resolution shown above. Portable monitors should be compact, easy to use with loud and bright alerts as standard. They must have marine type approval (e.g. MED wheelmark) which demonstrates their ability to perform in marine environments.
Solutions
I-Test & I-Test Manager
Fully automated solution for testing and verifying your Gas-Pro and T4
Read MoreConfined (Enclosed) Space Testing
Process Overview
From 1st July 2016, SOLAS Resolution MSC.380(94) requires specific classes of vessels to carry appropriate atmosphere testing equipment that is capable of measuring concentrations of oxygen, flammable gases or vapours, hydrogen sulphide and carbon monoxide prior to entry into enclosed spaces.
The SOLAS document: ‘Guidelines to facilitate the selection of portable atmosphere testing instruments for enclosed spaces as required by SOLAS regulation XI-1/7’ highlights specific portable instrument attributes including (not limited to) the ability to remote sample, to perform a self-test, to have a minimum battery run-time of 10 hours and have clear instructions.
Voluntary compliance with this SOLAS regulation has been highly recommended since 1st January 2015 when the enclosed space entry and rescue drill requirement (Chapter III, regulation 19) came into effect.
Gas Detection
Entering confined spaces should be avoided when possible. However, it may be necessary to survey a hold, clean a tank, or repair damage. If entry to a confined space cannot be avoided, the correct permits to work should be obtained, and good confined space entry procedures should be adhered to. Confined spaces are everywhere aboard ship, a space may not be entirely confined, so gases can seep in through piping or vents. Noxious gases can be given off by rotting materials, running engines or vessel cargo. Oxygen makes up around 20.9% of air. A drop to below 19.5% is considered hazardous. Welders, running motors, even rusting metal can reduce oxygen enough to kill in a space that is only opened occasionally.
Portable monitors that offer user focused functionality such as the Pre-Entry Check capability of Gas-Pro can guide crew-members through the pre-entry process as well as providing important data on procedures carried out and gas levels experienced.
Solutions
I-Test & I-Test Manager
Fully automated solution for testing and verifying your Gas-Pro and T4
Read MoreInert Space Monitoring
Process Overview
Cargo tanks carry a multitude of liquids; these can be flammable and/or toxic. Many of these liquids are protected by creating an inert atmosphere above the cargo. This can reduce oxidation, limit the potential for fire or reduce the potential for rust if cargo vessels are empty. An inert space on-board a ship can be maintained using engine exhaust, nitrogen, or other gas mixtures. It is common practise for empty tanks spaces to remain inert in readiness for the next cargo load.
Gas Detection
Inert spaces are immediately dangerous to life as by their very definition they contain no oxygen. These spaces must be monitored closely during the ship’s voyage, meaning that portable monitors need to be available and ready for use.
Inert gas monitors have the ability to measure flammable gases and/or vapours without oxygen being present. This requires infra-red (IR) technology as the more traditional pellistor/catalytic bead type LEL detectors require oxygen to function.
IR sensor technology also allows measurement of flammable gas concentration over the much larger %vol range which is important since traditional pellistor/catalytic bead detectors are usually limited to measuring up to 100% LEL concentrations.
Solutions
Gas-Pro TK
Gas-Pro TK integrates innovative safety features and an intuitive, rugged design to provide advanced protections for those working in harsh environments.
Read MoreI-Test & I-Test Manager
Fully automated solution for testing and verifying your Gas-Pro and T4
Read MoreConfined (Enclosed) Space Entry (CSE)
Process Overview
On 1 January 2015, within SOLAS Resolution MSC.350(92), it became mandatory for all crew members with enclosed space entry or rescue responsibilities to participate in an enclosed space entry and rescue drill. These drills are to be held on board the ship at least once every two months.
This regulation states the drill must include:
- checks and use of PPE (Personal Protective Equipment)
- checks and use of communications equipment and procedure
- checks and use of atmosphere measuring devices
- checks and use of rescue equipment
- instruction on first aid and resuscitation
SOLAS Resolution A.1050(27) defines an enclosed space as:
“2.1 Enclosed space means a space which has any of the following characteristics:
1. limited openings for entry and exit;
2. inadequate ventilation; and
3. is not designed for continuous worker occupancy,
and includes, but is not limited to, cargo spaces, double bottoms, fuel tanks, ballast tanks, cargo pump-rooms, cargo compressor rooms, cofferdams, chain lockers, void spaces, duct keels, inter-barrier spaces, boilers, engine crankcases, engine scavenge air receivers, sewage tanks, and adjacent connected spaces. This list is not exhaustive and a list should be produced on a ship-by-ship basis to identify enclosed spaces.”
Gas Detection
Entering a confined (enclosed) space is a dangerous activity. Not only should crew members be trained in the use of portable gas monitors, they should also be able to take part in rescue drills as dictated in the SOLAS resolution shown above. Portable monitors should be compact, easy to use with loud and bright alerts as standard. They must have marine type approval (e.g. MED wheelmark) which demonstrates their ability to perform in marine environments.
Solutions
I-Test & I-Test Manager
Fully automated solution for testing and verifying your Gas-Pro and T4
Read MoreConfined (Enclosed) Space Testing
Process Overview
From 1st July 2016, SOLAS Resolution MSC.380(94) requires specific classes of vessels to carry appropriate atmosphere testing equipment that is capable of measuring concentrations of oxygen, flammable gases or vapours, hydrogen sulphide and carbon monoxide prior to entry into enclosed spaces.
The SOLAS document: ‘Guidelines to facilitate the selection of portable atmosphere testing instruments for enclosed spaces as required by SOLAS regulation XI-1/7’ highlights specific portable instrument attributes including (not limited to) the ability to remote sample, to perform a self-test, to have a minimum battery run-time of 10 hours and have clear instructions.
Voluntary compliance with this SOLAS regulation has been highly recommended since 1st January 2015 when the enclosed space entry and rescue drill requirement (Chapter III, regulation 19) came into effect.
Gas Detection
Entering confined spaces should be avoided when possible. However, it may be necessary to survey a hold, clean a tank, or repair damage. If entry to a confined space cannot be avoided, the correct permits to work should be obtained, and good confined space entry procedures should be adhered to. Confined spaces are everywhere aboard ship, a space may not be entirely confined, so gases can seep in through piping or vents. Noxious gases can be given off by rotting materials, running engines or vessel cargo. Oxygen makes up around 20.9% of air. A drop to below 19.5% is considered hazardous. Welders, running motors, even rusting metal can reduce oxygen enough to kill in a space that is only opened occasionally.
Portable monitors that offer user focused functionality such as the Pre-Entry Check capability of Gas-Pro can guide crew-members through the pre-entry process as well as providing important data on procedures carried out and gas levels experienced.
Solutions
I-Test & I-Test Manager
Fully automated solution for testing and verifying your Gas-Pro and T4
Read MoreInert Space Monitoring
Process Overview
Cargo tanks carry a multitude of liquids; these can be flammable and/or toxic. Many of these liquids are protected by creating an inert atmosphere above the cargo. This can reduce oxidation, limit the potential for fire or reduce the potential for rust if cargo vessels are empty. An inert space on-board a ship can be maintained using engine exhaust, nitrogen, or other gas mixtures. It is common practise for empty tanks spaces to remain inert in readiness for the next cargo load.
Gas Detection
Inert spaces are immediately dangerous to life as by their very definition they contain no oxygen. These spaces must be monitored closely during the ship’s voyage, meaning that portable monitors need to be available and ready for use.
Inert gas monitors have the ability to measure flammable gases and/or vapours without oxygen being present. This requires infra-red (IR) technology as the more traditional pellistor/catalytic bead type LEL detectors require oxygen to function.
IR sensor technology also allows measurement of flammable gas concentration over the much larger %vol range which is important since traditional pellistor/catalytic bead detectors are usually limited to measuring up to 100% LEL concentrations.
Solutions
Gas-Pro TK
Gas-Pro TK integrates innovative safety features and an intuitive, rugged design to provide advanced protections for those working in harsh environments.
Read MoreI-Test & I-Test Manager
Fully automated solution for testing and verifying your Gas-Pro and T4
Read MoreConfined (Enclosed) Space Entry (CSE)
Process Overview
On 1 January 2015, within SOLAS Resolution MSC.350(92), it became mandatory for all crew members with enclosed space entry or rescue responsibilities to participate in an enclosed space entry and rescue drill. These drills are to be held on board the ship at least once every two months.
This regulation states the drill must include:
- checks and use of PPE (Personal Protective Equipment)
- checks and use of communications equipment and procedure
- checks and use of atmosphere measuring devices
- checks and use of rescue equipment
- instruction on first aid and resuscitation
SOLAS Resolution A.1050(27) defines an enclosed space as:
“2.1 Enclosed space means a space which has any of the following characteristics:
1. limited openings for entry and exit;
2. inadequate ventilation; and
3. is not designed for continuous worker occupancy,
and includes, but is not limited to, cargo spaces, double bottoms, fuel tanks, ballast tanks, cargo pump-rooms, cargo compressor rooms, cofferdams, chain lockers, void spaces, duct keels, inter-barrier spaces, boilers, engine crankcases, engine scavenge air receivers, sewage tanks, and adjacent connected spaces. This list is not exhaustive and a list should be produced on a ship-by-ship basis to identify enclosed spaces.”
Gas Detection
Entering a confined (enclosed) space is a dangerous activity. Not only should crew members be trained in the use of portable gas monitors, they should also be able to take part in rescue drills as dictated in the SOLAS resolution shown above. Portable monitors should be compact, easy to use with loud and bright alerts as standard. They must have marine type approval (e.g. MED wheelmark) which demonstrates their ability to perform in marine environments.
Solutions
I-Test & I-Test Manager
Fully automated solution for testing and verifying your Gas-Pro and T4
Read MoreConfined (Enclosed) Space Testing
Process Overview
From 1st July 2016, SOLAS Resolution MSC.380(94) requires specific classes of vessels to carry appropriate atmosphere testing equipment that is capable of measuring concentrations of oxygen, flammable gases or vapours, hydrogen sulphide and carbon monoxide prior to entry into enclosed spaces.
The SOLAS document: ‘Guidelines to facilitate the selection of portable atmosphere testing instruments for enclosed spaces as required by SOLAS regulation XI-1/7’ highlights specific portable instrument attributes including (not limited to) the ability to remote sample, to perform a self-test, to have a minimum battery run-time of 10 hours and have clear instructions.
Voluntary compliance with this SOLAS regulation has been highly recommended since 1st January 2015 when the enclosed space entry and rescue drill requirement (Chapter III, regulation 19) came into effect.
Gas Detection
Entering confined spaces should be avoided when possible. However, it may be necessary to survey a hold, clean a tank, or repair damage. If entry to a confined space cannot be avoided, the correct permits to work should be obtained, and good confined space entry procedures should be adhered to. Confined spaces are everywhere aboard ship, a space may not be entirely confined, so gases can seep in through piping or vents. Noxious gases can be given off by rotting materials, running engines or vessel cargo. Oxygen makes up around 20.9% of air. A drop to below 19.5% is considered hazardous. Welders, running motors, even rusting metal can reduce oxygen enough to kill in a space that is only opened occasionally.
Portable monitors that offer user focused functionality such as the Pre-Entry Check capability of Gas-Pro can guide crew-members through the pre-entry process as well as providing important data on procedures carried out and gas levels experienced.
Solutions
I-Test & I-Test Manager
Fully automated solution for testing and verifying your Gas-Pro and T4
Read MoreInert Space Monitoring
Process Overview
Cargo tanks carry a multitude of liquids; these can be flammable and/or toxic. Many of these liquids are protected by creating an inert atmosphere above the cargo. This can reduce oxidation, limit the potential for fire or reduce the potential for rust if cargo vessels are empty. An inert space on-board a ship can be maintained using engine exhaust, nitrogen, or other gas mixtures. It is common practise for empty tanks spaces to remain inert in readiness for the next cargo load.
Gas Detection
Inert spaces are immediately dangerous to life as by their very definition they contain no oxygen. These spaces must be monitored closely during the ship’s voyage, meaning that portable monitors need to be available and ready for use.
Inert gas monitors have the ability to measure flammable gases and/or vapours without oxygen being present. This requires infra-red (IR) technology as the more traditional pellistor/catalytic bead type LEL detectors require oxygen to function.
IR sensor technology also allows measurement of flammable gas concentration over the much larger %vol range which is important since traditional pellistor/catalytic bead detectors are usually limited to measuring up to 100% LEL concentrations.
Solutions
Gas-Pro TK
Gas-Pro TK integrates innovative safety features and an intuitive, rugged design to provide advanced protections for those working in harsh environments.
Read MoreI-Test & I-Test Manager
Fully automated solution for testing and verifying your Gas-Pro and T4
Read MoreConfined (Enclosed) Space Entry (CSE)
Process Overview
On 1 January 2015, within SOLAS Resolution MSC.350(92), it became mandatory for all crew members with enclosed space entry or rescue responsibilities to participate in an enclosed space entry and rescue drill. These drills are to be held on board the ship at least once every two months.
This regulation states the drill must include:
- checks and use of PPE (Personal Protective Equipment)
- checks and use of communications equipment and procedure
- checks and use of atmosphere measuring devices
- checks and use of rescue equipment
- instruction on first aid and resuscitation
SOLAS Resolution A.1050(27) defines an enclosed space as:
“2.1 Enclosed space means a space which has any of the following characteristics:
1. limited openings for entry and exit;
2. inadequate ventilation; and
3. is not designed for continuous worker occupancy,
and includes, but is not limited to, cargo spaces, double bottoms, fuel tanks, ballast tanks, cargo pump-rooms, cargo compressor rooms, cofferdams, chain lockers, void spaces, duct keels, inter-barrier spaces, boilers, engine crankcases, engine scavenge air receivers, sewage tanks, and adjacent connected spaces. This list is not exhaustive and a list should be produced on a ship-by-ship basis to identify enclosed spaces.”
Gas Detection
Entering a confined (enclosed) space is a dangerous activity. Not only should crew members be trained in the use of portable gas monitors, they should also be able to take part in rescue drills as dictated in the SOLAS resolution shown above. Portable monitors should be compact, easy to use with loud and bright alerts as standard. They must have marine type approval (e.g. MED wheelmark) which demonstrates their ability to perform in marine environments.
Solutions
I-Test & I-Test Manager
Fully automated solution for testing and verifying your Gas-Pro and T4
Read MoreConfined (Enclosed) Space Testing
Process Overview
From 1st July 2016, SOLAS Resolution MSC.380(94) requires specific classes of vessels to carry appropriate atmosphere testing equipment that is capable of measuring concentrations of oxygen, flammable gases or vapours, hydrogen sulphide and carbon monoxide prior to entry into enclosed spaces.
The SOLAS document: ‘Guidelines to facilitate the selection of portable atmosphere testing instruments for enclosed spaces as required by SOLAS regulation XI-1/7’ highlights specific portable instrument attributes including (not limited to) the ability to remote sample, to perform a self-test, to have a minimum battery run-time of 10 hours and have clear instructions.
Voluntary compliance with this SOLAS regulation has been highly recommended since 1st January 2015 when the enclosed space entry and rescue drill requirement (Chapter III, regulation 19) came into effect.
Gas Detection
Entering confined spaces should be avoided when possible. However, it may be necessary to survey a hold, clean a tank, or repair damage. If entry to a confined space cannot be avoided, the correct permits to work should be obtained, and good confined space entry procedures should be adhered to. Confined spaces are everywhere aboard ship, a space may not be entirely confined, so gases can seep in through piping or vents. Noxious gases can be given off by rotting materials, running engines or vessel cargo. Oxygen makes up around 20.9% of air. A drop to below 19.5% is considered hazardous. Welders, running motors, even rusting metal can reduce oxygen enough to kill in a space that is only opened occasionally.
Portable monitors that offer user focused functionality such as the Pre-Entry Check capability of Gas-Pro can guide crew-members through the pre-entry process as well as providing important data on procedures carried out and gas levels experienced.
Solutions
I-Test & I-Test Manager
Fully automated solution for testing and verifying your Gas-Pro and T4
Read MoreConfined (Enclosed) Space Entry (CSE)
Process Overview
On 1 January 2015, within SOLAS Resolution MSC.350(92), it became mandatory for all crew members with enclosed space entry or rescue responsibilities to participate in an enclosed space entry and rescue drill. These drills are to be held on board the ship at least once every two months.
This regulation states the drill must include:
- checks and use of PPE (Personal Protective Equipment)
- checks and use of communications equipment and procedure
- checks and use of atmosphere measuring devices
- checks and use of rescue equipment
- instruction on first aid and resuscitation
SOLAS Resolution A.1050(27) defines an enclosed space as:
“2.1 Enclosed space means a space which has any of the following characteristics:
1. limited openings for entry and exit;
2. inadequate ventilation; and
3. is not designed for continuous worker occupancy,
and includes, but is not limited to, cargo spaces, double bottoms, fuel tanks, ballast tanks, cargo pump-rooms, cargo compressor rooms, cofferdams, chain lockers, void spaces, duct keels, inter-barrier spaces, boilers, engine crankcases, engine scavenge air receivers, sewage tanks, and adjacent connected spaces. This list is not exhaustive and a list should be produced on a ship-by-ship basis to identify enclosed spaces.”
Gas Detection
Entering a confined (enclosed) space is a dangerous activity. Not only should crew members be trained in the use of portable gas monitors, they should also be able to take part in rescue drills as dictated in the SOLAS resolution shown above. Portable monitors should be compact, easy to use with loud and bright alerts as standard. They must have marine type approval (e.g. MED wheelmark) which demonstrates their ability to perform in marine environments.
Solutions
I-Test & I-Test Manager
Fully automated solution for testing and verifying your Gas-Pro and T4
Read MoreConfined (Enclosed) Space Testing
Process Overview
From 1st July 2016, SOLAS Resolution MSC.380(94) requires specific classes of vessels to carry appropriate atmosphere testing equipment that is capable of measuring concentrations of oxygen, flammable gases or vapours, hydrogen sulphide and carbon monoxide prior to entry into enclosed spaces.
The SOLAS document: ‘Guidelines to facilitate the selection of portable atmosphere testing instruments for enclosed spaces as required by SOLAS regulation XI-1/7’ highlights specific portable instrument attributes including (not limited to) the ability to remote sample, to perform a self-test, to have a minimum battery run-time of 10 hours and have clear instructions.
Voluntary compliance with this SOLAS regulation has been highly recommended since 1st January 2015 when the enclosed space entry and rescue drill requirement (Chapter III, regulation 19) came into effect.
Gas Detection
Entering confined spaces should be avoided when possible. However, it may be necessary to survey a hold, clean a tank, or repair damage. If entry to a confined space cannot be avoided, the correct permits to work should be obtained, and good confined space entry procedures should be adhered to. Confined spaces are everywhere aboard ship, a space may not be entirely confined, so gases can seep in through piping or vents. Noxious gases can be given off by rotting materials, running engines or vessel cargo. Oxygen makes up around 20.9% of air. A drop to below 19.5% is considered hazardous. Welders, running motors, even rusting metal can reduce oxygen enough to kill in a space that is only opened occasionally.
Portable monitors that offer user focused functionality such as the Pre-Entry Check capability of Gas-Pro can guide crew-members through the pre-entry process as well as providing important data on procedures carried out and gas levels experienced.
Solutions
I-Test & I-Test Manager
Fully automated solution for testing and verifying your Gas-Pro and T4
Read MoreGas Distribution
The gas network connects producers, processors, storage, transmission and distribution functions. Gas distribution describes the activity of providing piped gas (commonly methane, though Town-Gas used in some regions includes blends of hydrogen, methane and carbon dioxide) to industrial, commercial and residential properties. The gas is used for heating, hot water and cooking. A network of pipelines, storage facilities, pressure stations and regulators ensure constant availability of this resource. The operators of this network are responsible for its safe operation which includes finding and repairing reported leaks.
Methane is flammable at levels between 4.4% vol (Lower Explosive Limit - LEL) and 15% vol (Upper Explosive Limit - UEL). Methane in high concentrations may displace oxygen at levels above the UEL, especially in confined spaces. Decreased oxygen can cause suffocation and loss of consciousness. It can also cause headache, dizziness, weakness, nausea, vomiting, and loss of coordination.
With over 40 years experience in gas detection and a network of trained distributors and service agents, supporting Gas Distribution clients around the world, end users who have selected Crowcon equipment include international gas distribution companies as well as regional suppliers.
Pressure Management
Process Overview
Gas travels from gas terminals through the high pressure transmission system, then through the medium and low pressure distribution networks to reach the consumer. Compressor stations and pressure letdown facilities within this system constantly manage the pressure.
Compressor stations are one of the most important components of the natural gas transport system; it is the act of compressing the gas which allows it to travel through the pipeline. Compressor stations are usually located every 40 to 70 miles (64 to 112 km) along the network to boost the pressure that is lost through the friction of the natural gas moving through the pipe; however this is dependent on region and conditions. Compressor stations are also responsible for maintaining the gas, including scrubbers, strainers or filter separators which remove liquids, dirt, particles, and other impurities. Other hydrocarbons may also condense out of the gas as it travels, which are also removed.
Gas Detection
Pressure management stations are an intricate installation of compressors, filters, cooling systems and mufflers. Much of the asset is above ground and includes valves and pipe joins and flanges.
Infrared detectors are well suited to this environment where high volumes of gas may occur that might damage traditional sensors for measuring up to LEL levels. Facilities are commonly open to the elements so sampling systems can be employed, installed to protect the fixed detectors from water damage.
Personnel may wear portable flammable detectors as well as using leak location tools for either regular LDAR (leak detection and repair) activities or while investigating a known leak. In this regard, keeping personnel away from the potential hazard is paramount.
Solutions
Gas-Pro IR
This latest offering detects methane, pentane or propane using infrared IR sensor technology
Read MoreLocal Storage
Process Overview
Storage plays a vital role in maintaining the reliability of supply needed to meet the demands of users and can be stored for an indefinite period of time. Gas is stored to ensure availability and aid peak supply requirements, for example in the winter months when usage increases. Storage can be below or above ground and usually located close to regional centers.
Gas Detection
Maintaining the integrity of storage facilities is paramount, early warning of any leak improves the safety of the facility and those living or working around it. Fixed detection focused on flanges and any potential weak points can give local alerts as well as taking executive action to adapt gas flow and storage rates.
Though often un-manned, any personnel visiting or working on-site should carry out activity specific risk assessments. Any activities including welding, soldering, cutting and brazing should be covered under a Hot Work permit, and require the use of area and personal detectors to maintain a safe working atmosphere.
Leak locators that are able to survey large areas as well as intricate pipework, that is commonly out of reach, quickly and without putting the user in danger are vital in this environment.
Solutions
Gas-Pro IR
This latest offering detects methane, pentane or propane using infrared IR sensor technology
Read MoreLow-Pressure/Second Stage Distribution
Process Overview
Second stage distribution covers the final regulator and the pipelines used to transport gas to homes as well as commercial and industrial facilities. Regulators are used to control the flow lowering the pressure across the supply. Relief valves are installed on pipelines to vent gas harmlessly, if a line becomes over-pressured and the regulators malfunction as an added safety measure.
Pipelines are commonly located below-ground, however in some areas this is not possible. Historically pipelines were made of cast iron, which over time have become less reliable. Many regions are now replacing these pipelines with the more modern plastic solutions. Gas operators regularly survey pipelines to ensure integrity as well as responding to gas escape reports.
Gas Detection
Portable detectors are commonly used to protect personnel carrying out both regular pipeline surveys as well as emergency response teams. These teams may also respond to residential and business escape reports, where carbon monoxide can also be a potential hazard. Carbon monoxide (CO) is a colorless, odourless, tasteless yet poisonous gas formed during the incomplete combustion of any carbon fuel (e.g. natural gas or methane).
Solutions
Above Ground Pipelines
Process Overview
While the majority of supply and service lines are underground, sometimes this is impractical. For example, crossing trainlines, rivers or major roads. In some regions, gas supply pipes are also located up the sides of buildings, reducing the risk of leaks within the premises.
Gas Detection
Above ground pipelines offer further challenges with respect to leak survey and leak locating practices. They are by nature 'out of reach' and often in extremely inaccessible areas, sometimes with restricted or gated access. In order to effectively carry out surveys, lifting equipment is commonly employed to ensure the safety of personnel carrying out this task. This is both costly and puts the employee into a potentially hazardous area. Leak detectors that offer detection at distance for even the smallest of escapes improve efficiency while ensuring the safety of personnel.
Solutions
CNG Filling Station
Process Overview
In recent years, the number of gas fuelled cars – and the number of gas fuel stations – has grown strongly. A key driver for this is environmental issues. In comparison to the more traditional fuels (e.g. gasoline and diesel) use of natural gas to fuel cars results in lower pollutant emissions, such as soot and sulphur dioxide. It also avoids the production of nitrous oxide and nitrogen dioxide, which is being increasingly recognised as the cause of health problems in cities due to the recent growth in popularity of diesel engines.
Gas Detection
The storage of these gases poses additional challenges for the fuel station over those presented by the liquid fuels. There is much guidance specifically on the safe storage and handling of this highly flammable gas, as well as general regulation relating to explosive gases and vapours.
Anyone responsible for gas fuel stations must ensure that suitable systems are in place to detect any gas leak and address it before a risk of explosion can develop. Detectors placed at potential risk points within the delivery subsystem, such as pipe joins and compressor station contribute to the overall safety of installations.
