Crowcon exhibited at the World Hydrogen Summit & Exhibition 2022 on the 9th – 11th May 2022 as part of the event designed to advance development in the hydrogen sector. Based in Rotterdam and produced by the Sustainable Energy Council (SEC), this year’s exhibition was the first Crowcon has attended. We were excited to be part of an occasion which fosters connections and collaboration between those at the forefront of the heavy industry and drives the hydrogen sector forward.
Our team representatives met various industry peers and showcased our Hydrogen solutions for gas detection. Our MPS sensor offers a higher standard of flammable gas detection thanks to its pioneering advanced molecular property spectrometer (MPS™) technology that can detect and accurately identify over 15 different flammable gases. This showcased an ideal solution for hydrogen detection due to hydrogen having proprieties that allow for easy ignition and higher burn intensity compared to that of petrol or diesel, therefore poses a real explosion risk. To find out more read our blog.
Our MPS technology had interest due to this not requiring calibration throughout the life cycle of the sensor, and detects flammable gases without the risk of poisoning or false alarms, thereby having a significant saving on total cost of ownership and reduce interaction with units, ultimately providing peace of mind and less risk for operators.
The Summit allowed us to understand the current state of the hydrogen market, including key players and current projects, allowing for potential developed a greater understanding of our product needs in order to play a major role in the future of hydrogen gas detection.
Electrochemical sensors are the most used in diffusion mode in which gas in the ambient environment enters through a hole in the face of the cell. Some instruments use a pump to supply air or gas samples to the sensor. A PTFE membrane is fitted over the hole to prevent water or oils from entering the cell. Sensor ranges and sensitivities can be varied in design by using different size holes. Larger holes provide higher sensitivity and resolution, whereas smaller holes reduce sensitivity and resolution but increase the range.
Benefits
Electrochemical sensors have several benefits.
Can be specific to a particular gas or vapor in the parts-per-million range. However, the degree of selectivity depends on the type of sensor, the target gas and the concentration of gas the sensor is designed to detect.
High repeatability and accuracy rate. Once calibrated to a known concentration, the sensor will provide an accurate reading to a target gas that is repeatable.
Not susceptible to poisoning by other gases, with the presence of other ambient vapours will not shorten or curtail the life of the sensor.
Less expensive than most other gas detection technologies, such as IR or PID technologies. Electrochemical sensors are also more economical.
Issues with cross-sensitivity
Cross-sensitivity occurs when a gas other than the gas being monitored/detected can affect the reading given by an electrochemical sensor. This causes the electrode within the sensor to react even if the target gas is not actually present, or it causes an otherwise inaccurate reading and/or alarm for that gas. Cross-sensitivity may cause several types of inaccurate reading in electrochemical gas detectors. These can be positive (indicating the presence of a gas even though it is not actually there or indicating a level of that gas above its true value), negative (a reduced response to the target gas, suggesting that it is absent when it is present, or a reading that suggests there is a lower concentration of the target gas than there is), or the interfering gas can cause inhibition.
Factors affecting electrochemical sensor life
There are three main factors that affect the sensor life including temperature, exposure to extremely high gas concentrations and humidity. Other factors include sensor electrodes and extreme vibration and mechanical shocks.
Temperature extremes can affect sensor life. The manufacturer will state an operating temperature range for the instrument: typically -30˚C to +50˚C. High quality sensors will, however, be able to withstand temporary excursions beyond these limits. Short (1-2 hours) exposure to 60-65˚C for H2S or CO sensors (for example) is acceptable, but repeated incidents will result in evaporation of the electrolyte and shifts in the baseline (zero) reading and slower response.
Exposure to extremely high gas concentrations can also compromise sensor performance. Electrochemical sensors are typically tested by exposure to as much as ten-times their design limit. Sensors constructed using high quality catalyst material should be able to withstand such exposures without changes to chemistry or long-term performance loss. Sensors with lower catalyst loading may suffer damage.
The most considerable influence on sensor life is humidity. The ideal environmental condition for electrochemical sensors is 20˚Celsius and 60% RH (relative humidity). When the ambient humidity increases beyond 60%RH water will be absorbed into the electrolyte causing dilution. In extreme cases the liquid content can increase by 2-3 times, potentially resulting in leakage from the sensor body, and then through the pins. Below 60%RH water in the electrolyte will begin to de-hydrate. The response time may be significantly extended as the electrolyte or dehydrated. Sensor electrodes can in unusual conditions be poisoned by interfering gases that adsorb onto the catalyst or react with it creating by-products which inhibit the catalyst.
Extreme vibration and mechanical shocks can also harm sensors by fracturing the welds that bond the platinum electrodes, connecting strips (or wires in some sensors) and pins together.
‘Normal’ life expectancy of electrochemical Sensor
Electrochemical sensors for common gases such as carbon monoxide or hydrogen sulphide have an operational life typically stated at 2-3 years. More exotic gas sensor such as hydrogen fluoride may have a life of only 12-18 months. In ideal conditions (stable temperature and humidity in the region of 20˚C and 60%RH) with no incidence of contaminants, electrochemical sensors have been known to operate more than 4000 days (11 years). Periodic exposure to the target gas does not limit the life of these tiny fuel cells: high quality sensors have a large amount of catalyst material and robust conductors which do not become depleted by the reaction.
Products
As electrochemical sensors are more economical, We have a range of portable products and fixed products that use this type of sensor to detect gases.
To explore more, visit our technical page for more information.
Pellistor sensors consist of two matched wire coils, each embedded in a ceramic bead. Current is passed through the coils, heating the beads to approximately 230˚C. The bead becomes hot from the combustion, resulting in a temperature difference between this active and the other ‘reference’ bead. This causes a difference in resistance, which is measured; the amount of gas present is directly proportional to the resistance change, so gas concentration as a percentage of its lower explosive limit (% LEL*) can be accurately determined. Flammable gas burns on the bead and the additional heat generated produces an increase in coil resistance which is measured by the instrument to indicate gas concentration. Pellistor sensors are widely used throughout industry including on oil rigs, at refineries, and for underground construction purposes such as mines, and tunnels.
Benefits of Pellistor Sensors?
Pellistor sensors are relatively low in cost due to differences in the level of technology in comparison to the more complex technologies like IR sensors, however, they may be required to be replaced more frequently. With a linear output corresponding to the gas concentration, correction factors can be used to calculate the approximate response of pellistors to other flammable gases, which can make pellistors a good choice when there are multiple flammable gases and vapours present.
Factors affecting Pellistor Sensor Life
The two main factors that shorten the sensor life include exposure to high gas concentration and poisoning or inhibition of the sensor. Extreme mechanical shock or vibration can also affect the sensor life.
The capacity of the catalyst surface to oxidise the gas reduces when it has been poisoned or inhibited. Sensor lifetimes of up to ten years is known in some applications where inhibiting or poisoning compounds are not present. Higher power pellistors have larger beads, hence more catalyst, and that greater catalytic activity ensures less vulnerability to poisoning. More porous beads allow easier access of the gas to more catalyst allowing greater catalytic activity from a surface volume instead of just a surface area. Skilled initial design and sophisticated manufacturing processes ensure maximum bead porosity.
Strength of the bead is also of great importance since exposure to high gas concentrations (>100% LEL) may compromise sensor integrity causing cracking. Performance is affected and often offsets in the zero/base-line signal result. Incomplete combustion results in carbon deposits on the bead: the carbon ‘grows’ in the pores and causes mechanical damage or just gets in the way of gas reaching the pellistor. The carbon may however be burned off over time to re-reveal catalytic sites.
Extreme mechanical shock or vibration can in rare cases cause a break in the pellistor coils. This issue is more prevalent on portable rather than fixed-point gas detectors as they are more likely to be dropped, and the pellistors used are lower power (to maximise battery life) and thus use more delicate thinner wire coils.
What happens when a Pellistor is poisoned?
A poisoned pellistor remains electrically operational but may fail to respond to gas as it will not produce an output when exposed to flammable gas. This means a detector would not go into alarm, giving the impression that the environment is safe.
Compounds containing silicon, lead, sulphur, and phosphates at just a few parts per million (ppm) can impair pellistor performance. Therefore, whether it’s something in your general working environment, or something as harmless as cleaning equipment or hand cream, bringing it near to a pellistor could mean you are compromising your sensor’s effectiveness without even realising it.
Why are silicones bad?
Silicones have their virtues, but they may be more common than you first thought. Some examples include sealants, adhesives, lubricants, and thermal and electrical insulation. Silicones, have the ability to poison a sensor on a pellistor at extremely low levels, because they act cumulatively a bit at a time.
Products
Our portable products all use low power portables pellistor beads. This prolongs battery life but can make them prone to poisoning. Which is why we offer alternatives that do not poison, such as the IR and MPS sensors. Our fixed products use a porous high energy fixed pellistor.
To explore more, visit our technical page for more information.
Gas detectors are used extensively within many industries (such as water treatment, refinery, petrochemical, steel and construction to name a few) to protect personnel and equipment from dangerous gases and their effects. Users of portable and fixed devices will be familiar with the potentially significant costs of keeping their instruments operating safely over their operational life. Gas sensors are understood to provide a measurement of the concentration of some analyte of interest, such as CO (carbon monoxide), CO2 (carbon dioxide), or NOx (nitrogen oxide). There are two most used gas sensors within industrial applications: electrochemical for toxic gases and oxygen measurement, and pellistors (or catalytic beads) for flammable gases. In recent years, the introduction of both Oxygen and MPS (Molecular Property Spectrometer) sensors have allowed for improved safety.
How do I know when my sensor has failed?
There have been several patents and techniques applied to gas detectors over the past few decades which claim to be able to determine when an electrochemical sensor has failed. Most of these however, only infer that the sensor is operating through some form of electrode stimulation and might provide a false sense of security. The only sure method of demonstrating that a sensor is working is to apply test gas and measure the response: a bump test or full calibration.
Electrochemical Sensor
Electrochemical sensors are the most used in diffusion mode in which gas in the ambient environment enters through a hole in the face of the cell. Some instruments use a pump to supply air or gas samples to the sensor. A PTFE membrane is fitted over the hole to prevent water or oils from entering the cell. Sensor ranges and sensitivities can be varied in design by using different size holes. Larger holes provide higher sensitivity and resolution, whereas smaller holes reduce sensitivity and resolution but increase the range.
Factors affecting Electrochemical Sensor Life
There are three main factors that affect the sensor life including temperature, exposure to extremely high gas concentrations and humidity. Other factors include sensor electrodes and extreme vibration and mechanical shocks.
Temperature extremes can affect sensor life. The manufacturer will state an operating temperature range for the instrument: typically -30˚C to +50˚C. High quality sensors will, however, be able to withstand temporary excursions beyond these limits. Short (1-2 hours) exposure to 60-65˚C for H2S or CO sensors (for example) is acceptable, but repeated incidents will result in evaporation of the electrolyte and shifts in the baseline (zero) reading and slower response.
Exposure to extremely high gas concentrations can also compromise sensor performance. Electrochemical sensors are typically tested by exposure to as much as ten-times their design limit. Sensors constructed using high quality catalyst material should be able to withstand such exposures without changes to chemistry or long-term performance loss. Sensors with lower catalyst loading may suffer damage.
The most considerable influence on sensor life is humidity. The ideal environmental condition for electrochemical sensors is 20˚Celsius and 60% RH (relative humidity). When the ambient humidity increases beyond 60%RH water will be absorbed into the electrolyte causing dilution. In extreme cases the liquid content can increase by 2-3 times, potentially resulting in leakage from the sensor body, and then through the pins. Below 60%RH water in the electrolyte will begin to de-hydrate. The response time may be significantly extended as the electrolyte or dehydrated. Sensor electrodes can in unusual conditions be poisoned by interfering gases that adsorb onto the catalyst or react with it creating by-products which inhibit the catalyst.
Extreme vibration and mechanical shocks can also harm sensors by fracturing the welds that bond the platinum electrodes, connecting strips (or wires in some sensors) and pins together.
‘Normal’ Life Expectancy of Electrochemical Sensor
Electrochemical sensors for common gases such as carbon monoxide or hydrogen sulphide have an operational life typically stated at 2-3 years. More exotic gas sensor such as hydrogen fluoride may have a life of only 12-18 months. In ideal conditions (stable temperature and humidity in the region of 20˚C and 60%RH) with no incidence of contaminants, electrochemical sensors have been known to operate more than 4000 days (11 years). Periodic exposure to the target gas does not limit the life of these tiny fuel cells: high quality sensors have a large amount of catalyst material and robust conductors which do not become depleted by the reaction.
Pellistor Sensor
Pellistor sensors consist of two matched wire coils, each embedded in a ceramic bead. Current is passed through the coils, heating the beads to approximately 500˚C. Flammable gas burns on the bead and the additional heat generated produces an increase in coil resistance which is measured by the instrument to indicate gas concentration.
Factors affecting Pellistor Sensor Life
The two main factors that affect the sensor life include exposure to high gas concentration and poising or inhibition of the sensor. Extreme mechanical shock or vibration can also affect the sensor life. The capacity of the catalyst surface to oxidise the gas reduces when it has been poisoned or inhibited. Sensor life more than ten years is common in applications where inhibiting or poisoning compounds are not present. Higher power pellistors have greater catalytic activity and are less vulnerable to poisoning. More porous beads also have greater catalytic activity as their surface volume in increased. Skilled initial design and sophisticated manufacturing processes ensure maximum bead porosity. Exposure to high gas concentrations (>100%LEL) may also compromise sensor performance and create an offset in the zero/base-line signal. Incomplete combustion results in carbon deposits on the bead: the carbon ‘grows’ in the pores and creates mechanical damage. The carbon may however be burned off over time to re-reveal catalytic sites. Extreme mechanical shock or vibration can in rare cases also cause a break in the pellistor coils. This issue is more prevalent on portable rather than fixed-point gas detectors as they are more likely to be dropped, and the pellistors used are lower power (to maximise battery life) and thus use more delicate thinner wire coils.
How do I know when my sensor has failed?
A pellistor that has been poisoned remains electrically operational but may fail to respond to gas. Hence the gas detector and control system may appear to be in a healthy state, but a flammable gas leak may not be detected.
Oxygen Sensor
Our new lead-free, long-lasting oxygen sensor does not have compressed strands of lead the electrolyte has to penetrate, allowing a thick electrolyte to be used which means no leaks, no leak induced corrosion, and improved safety. The additional robustness of this sensor allows us to confidently offer a 5-year warranty for added piece of mind.
Long life-oxygen sensors have an extensive lifespan of 5-years, with less downtime, lower cost of ownership, and reduced environmental impact. They accurately measure oxygen over a broad range of concentrations from 0 to 30% volume and are the next generation of O2 gas detection.
MPS Sensor
MPS sensor provides advanced technology that removes the need to calibrate and provides a ‘True LEL (lower explosive limit)’ for reading for fifteen flammable gases but can detect all flammable gases in a multi-species environment, resulting in lower ongoing maintenance costs and reduced interaction with the unit. This reduces risk to personnel and avoids costly downtime. The MPS sensor is also immune to sensor poisoning.
Sensor failure due to poisoning can be a frustrating and costly experience. The technology in the MPS™ sensor is not affected by contaminates in the environment. Processes that have contaminates now have access to a solution that operates reliably with fail safe design to alert operator to offer a peace of mind for personnel and assets located in hazardous environment. It is now possible to detect multiple flammable gases, even in harsh environments, using just one sensor that does not require calibration and has an expected lifespan of at least 5 years.
Sensors play a key role when it comes to monitoring flammable gases and vapours. Environment, response time and temperature range are just some of the things to consider when deciding which technology is best.
In this blog, we’re highlighting the differences between pellistor (catalytic) sensors and infrared (IR) sensors, why there are pros and cons to both technologies, and how to know which is best to suit different environments.
Pellistor sensor
A pellistor gas sensor is a device used to detect combustible gases or vapours that fall within the explosive range to warn of rising gas levels. The sensor is a coil of platinum wire with a catalyst inserted inside to form a small active bead which lowers the temperature at which gas ignites around it. When a combustible gas is present the temperature and resistance of the bead increases in relation to the resistance of the inert reference bead. The difference in resistance can be measured, allowing measurement of gas present. Because of the catalysts and beads, a pellistor sensor is also known as a catalytic or catalytic bead sensor.
Originally created in the 1960’s by British scientist and inventor, Alan Baker, pellistor sensors were initially designed as a solution to the long-running flame safety lamp and canary techniques. More recently, the devices are used in industrial and underground applications such as mines or tunnelling, oil refineries and oil rigs.
Pellistor sensors are relatively lower in cost due to differences in the level of technology in comparison to IR sensors, however they may be required to be replaced more frequently.
With a linear output corresponding to the gas concentration, correction factors can be used to calculate the approximate response of pellistors to other flammable gases, which can make pellistors a good choice when there are multiple flammable vapours present.
Not only this but pellistors within fixed detectors with mV bridge outputs such as the Xgard type 3 are highly suited to areas that are hard to reach as calibration adjustments can take place at the local control panel.
On the other hand, pellistors struggle in environments where there is low or little oxygen, as the combustion process by which they work, requires oxygen. For this reason, confined space instruments which contain catalytic pellistor type LEL sensors often include a sensor for measuring oxygen.
In environments where compounds contain silicon, lead, sulphur and phosphates the sensor is susceptible to poisoning (irreversible loss of sensitivity) or inhibition (reversible loss of sensitivity), which can be a hazard to people in the workplace.
If exposed to high gas concentrations, pellistor sensors can be damaged. In such situations, pellistors do not ‘fail safe’, meaning no notification is given when an instrument fault is detected. Any fault can only be identified through bump testing prior to each use to ensure that performance is not being degraded.
IR sensor
Infrared sensor technology is based on the principle that Infrared (IR) light of a particular wavelength will be absorbed by the target gas. Typically there are two emitters within a sensor generating beams of IR light: a measurement beam with a wavelength that will be absorbed by the target gas, and a reference beam which will not be absorbed. Each beam is of equal intensity and is deflected by a mirror inside the sensor onto a photo-receiver. The resulting difference in intensity, between the reference and measurement beam, in the presence of the target gas is used to measure the concentration of gas present.
In many cases, infrared (IR) sensor technology can have a number of advantages over pellistors or be more reliable in areas where pellistor-based sensor performance can be impaired- including low oxygen and inert environments. Just the beam of infrared interacts with the surrounding gas molecules, giving the sensor the advantage of not facing the threat of poisoning or inhibition.
IR technology provides fail-safe testing. This means that if the infrared beam was to fail, the user would be notified of this fault.
Gas-Pro TK uses a dual IR sensor – the best technology for the specialist environments where standard gas detectors just won’t work, whether tank purging or gas freeing.
An example of one of our IR based detectors is the Crowcon Gas-Pro IR, ideal for the oil and gas industry, with the availability to detect methane, pentane or propane in potentially explosive, low oxygen environments where pellistor sensors may struggle. We also use a dual range %LEL and %Volume sensor in our Gas-Pro TK, which is suitable for measuring and switching between both measurements so it’s always safely operating to the correct parameter.
However, IR sensors aren’t all perfect as they only have a linear output to target gas; the response of an IR sensor to other flammable vapours then the target gas will be non-linear.
Like pellistors are susceptible to poisoning, IR sensors are susceptible to severe mechanical and thermal shock and also strongly affected by gross pressure changes. Additionally, infrared sensors cannot be used to detect Hydrogen gas, therefore we suggest using pellistors or electromechanical sensors in this circumstance.
The prime objective for safety is to select the best detection technology to minimise hazards in the workplace. We hope that by clearly identifying the differences between these two sensors we can raise awareness on how various industrial and hazardous environments can remain safe.
For further guidance on pellistor and IR sensors, you can download our whitepaper which includes illustrations and diagrams to help determine the best technology for your application.
Due to extreme heat in the Middle East climbing up to 50°C in the height of summer, the necessity for reliable gas detection is critical. In this blog, we’re focusing on the requirement for detection of hydrogen sulphide (H2S)- a long running challenge for the Middle East’s gas detection industry.
By combining a new trick with old technology, we’ve got the answer to reliable gas detection for environments in the harsh Middle Eastern climate. Our new High Temperature (HT) H2S sensor for XgardIQ has been revisited and improved by our team of Crowcon experts by using a combination of two ingenious adaptations to its original design.
In traditional H2S sensors, detection is based on electrochemical technology, where electrodes are used to detect changes induced in an electrolyte by the presence of the target gas. However, high temperatures combined with low humidity causes the electrolyte to dry out, impairing sensor performance so that the sensor has to be replaced regularly; meaning high replacement costs, time and efforts.
Making the new sensor so advanced from its predecessor is its ability to retain the moisture levels within the sensor, preventing evaporation even in high temperature climates. The updated sensor is based on electrolytic gel, adapted to make it more hygroscopic and avoiding dehydration for longer.
As well as this, the pore in the sensor housing has been reduced, limiting the moisture from escaping. This chart indicated weight loss which is indicative of moisture loss. When stored at 55°C or 65°C for a year just 3% of weight is lost. Another typical sensor would lose 50% of its weight in 100 days in the same conditions.
For optimal leak detection, our remarkable new sensor also features an optional remote sensor housing, while the transmitter’s displays screen and push-button controls are positioned for safe and easy access for operators up to 15metres away.
The results of our new HT H2S sensor for XgardIQ speak for themselves, with an operating environment of up to 70°C at 0-95%rh, as well featuring a 0-200ppm and T90 response time of less than 30 seconds. Unlike other sensors for detecting H2S, it offers a life expectancy of over 24 months, even in tough climates like the Middle East.
The answer to the Middle East’s gas detection challenges fall in the hands of our new sensor, providing its users with cost-effective and reliable performance.
Click here for more information about the Crowcon HT H2S sensor.
When something stops working, you rarely get a heads-up. When was the last time you flipped a switch, only for your light bulb to give up the ghost? Or have you had a cold, frosty morning this winter when your car simply won’t start?
We recently ran a series of articles call the “Seven Deadly Sins of Gas Detection”. By highlighting the most common causes and effects of each ”sin”, we wanted to provide managers and employees with a greater awareness of what we believe are the Seven Deadly Sins of gas detection, how to avoid them and save lives. For the same reason, we are sharing them as our blog posts for the next seven weeks.
Having recently shared our video on pellistors and how they work, we thought it would make sense to also post our video about PID (photo-ionisation detection). This is the technology of choice for monitoring exposure to toxic levels of another group of important gases – volatile organic compounds (VOCs).
Pellistor gas sensors (or catalytic bead gas sensors) have been the primary technology for detecting flammable gases since the ‘60s. Despite having discussed a number of issues relating to the detection of flammable gases and VOC, we have not yet looked at how pellistors work. To make up for this, we are including a video explanation, which we hope you will download and use as part of any training you are conducting
A pellistor is based on a Wheatstone bridge circuit, and includes two “beads”, both of which encase platinum coils. One of the beads (the ‘active’ bead) is treated with a catalyst, which lowers the temperature at which the gas around it ignites. This bead becomes hot from the combustion, resulting in a temperature difference between this active and the other ‘reference’ bead. This causes a difference in resistance, which is measured; the amount of gas present is directly proportional to it, so gas concentration as a percentage of its lower explosive limit (%LEL*) can be accurately determined.
The hot bead and electrical circuitry are contained in flameproof sensor housing, behind the sintered metal flame arrestor (or sinter) through which the gas passes. Confined within this sensor housing, which maintains an internal temperature of 500°C, controlled combustion can occur, isolated from the outside environment. In high gas concentrations, the combustion process can be incomplete, resulting in a layer of soot on the active bead. This will partially or completely impair performance. Care needs to be taken in environments where gas levels over 70% LEL may be encountered.
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