Blogs listed by category: Industries

An Introduction to the Marine Industry

The marine sector is a global industry and is wide ranging in terms of its applications and different types of vessels including FPSO vessels, ferries and submarines. 

The type of gas hazards that will be present, and subsequently the gas detection requirements, are heavily dependent on the application and the type of marine vessel being used. In this blog we’ll take a look at some of the most common gas hazards within the marine industry and in which applications they are most likely to occur. 

Floating Production, Storage, Offloading Units and Tankers 

Floating production, storage and offloading (FPSO) units, which are used in the production, processing and storage of oil, are home to many potential gas hazards. 

Firstly, there is the risk of fire and explosion hazards, which can lead to catastrophic damage and loss of life.  Combustible gas risks that may be present include methane, hydrogen, propane, LPG, solvents and gasoline fumes among others. Due to this risk, flammable gas detection is essential on FPSO vessels.  

FPSO units also have confined spaces in the form of inverted tanks or voids, meaning oxygen detectors are a must for these areas to protect from the risks of oxygen depletion which can cause mental confusion, nausea, weakness and in extreme cases loss of consciousness and death. 

Ferries 

Whilst ferries may not be home to as many gas hazards as other vessels, there are certainly still some to be aware of. On vehicle carrying ferries, for example, there may be a large build-up of emissions from vehicle exhausts which contain harmful gases such as carbon monoxide and nitrogen dioxide. Both gases are capable of causing damage to human health, causing issues such as nausea, confusion and disorientation, inflammation of the airways and increased vulnerability to respiratory infection. 

Submarines 

Submarines may be used for a variety of purposes including salvage and exploration operations, marine science and facility inspection and maintenance. On these vessels there may be a requirement for hydrogen detection in battery storage rooms. Whilst hydrogen is a non-toxic gas, if it builds up in environments without sufficient airflow it can displace oxygen in the air leading to risk of oxygen depletion. 

Our solutions 

Gas detection can be provided in both fixed and portable forms. Our portable gas detectors protect people against a wide range of gas hazards, and include T4x, Gas-Pro, T4 and Gas-Pro TK. Our fixed gas detectors are used where reliability, dependability and lack of false alarms are instrumental to efficient and effective protection of assets and areas. Now available through Crowcon, the Sensitron SMART S-MS MED fixed detector has been designed specifically for use in marine environments. The SMART S-MS MED is fully marine certified by Lloyd’s Register in accordance with MED/3.54 Regulation whilst also being SIL-2 certified. Also available is the Multiscan++MED control panel, also MED and SIL-2 certified, able to manage and monitor up to 64 gas detectors. 

To find out more on the gas hazards in the marine sector visit our industry page for more information.

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Gas Safety Protocols in Water Treatment

Water is vital to our daily lives, both for personal and domestic use and industrial/commercial applications. It is everywhere, promoting some chemical reactions and inhibiting others. Being used to clean surfaces, carry chemicals to where they are used and to carry unwanted chemicals away. Do anything and you create a gas somewhere in some quantity. Do anything with water there are so many permutations of things that can come together and react, dissolved gases that can come out of solution, dissolved liquids and solids that can react to generate gases. Additionally, you must determine what gases you generate when you collect, clean, store, transport or use water. Gas detectors must be chosen to suit the specific environment in which they operate, in this case highly humid, often dirty, but rarely outside the temperature range 4 to 30 degrees C. All the risks are present in these complex environments, with multiple toxic and flammable gas hazards and often the additional risk of oxygen depletion.

Gas Hazards

Apart from common gas hazards known in the industry; methane, hydrogen sulphide, and oxygen, there are bi-product gas hazards and cleaning material gas hazards that occur from purifying chemicals such as ammonia, chlorine, chlorine dioxide or ozone that are used in the decontamination of the waste and effluent water, or to remove microbes from clean water. There is great potential for many toxic or explosive gases to exist as a result of the chemicals used in the water industry. And added to these are chemicals that may be spilled or dumped into the waste system from industry, farming or building work.

Chlorine (Cl2) gas appears yellow green in colour, used to sterilise drinking water. However, most chlorine is used in the chemical industry with typical applications including water treatment as well as within the plastics and cleaning agents. Chlorine gas can be recognised by its pungent, irritating odour, which is like the odour of bleach. The strong smell may provide adequate warning to people that they are exposed. Cl2 itself is not flammable, but it can react explosively or form flammable compounds with other chemicals such as turpentine and ammonia.

Ammonia (NH3) is a compound of nitrogen and hydrogen and is a colourless and pungent gas, also known to be highly soluble when in contact with water. This means that NH3 dissolves quickly into the water supply. Found at very low levels in humans and in nature. It is also often used in some household cleaning solutions. Although NH3 has many benefits, it can be corrosive and dangerous in certain circumstances. Ammonia can enter wastewater from several different sources, including urine, manure, cleaning chemicals, process chemicals and amino acid products. If NH3 enters a copper piping system, it can cause extensive corrosion. If NH3 enters water, its toxicity varies depending on the exact pH of the water. It is possible for ammonia to break down into ammonium ions, which can react with other compounds present.

Chlorine dioxide (ClO2) is an oxidising gas commonly used to disinfect drinking water. When used in very small quantities, it is safe and does not lead to significant health risks. But ClO2 is a strong disinfectant that kills bacteria, viruses, and fungi, and when used in high doses, it can be dangerous to people since it can damage red blood cells and the lining of the gastrointestinal (GI) tract.

Ozone (O3) is a gas with an antiseptic smell and no colour that, mostly, forms naturally in the environment. When inhaled, ozone can have a range of harmful effects on the body. As it is colourless gas it is difficult to trace without an effective detection system in place. Even when relatively small amounts are inhaled, the gas can have a damaging impact on the respiratory tract, causing inflammation and chest pain, alongside coughing, shortness of breath and throat irritation. It can also act as a trigger causing diseases such as asthma to worsen.

Confined Space Entry

The pipelines used to transport water require regular cleaning and safety checks; during these operations, portable multi-gas monitors are used to protect the workforce. Pre-entry checks must be completed prior to entering any confined space and commonly O2, CO, H2S and CH4 are monitored. Confined spaces are small, so portable monitors must be compact and unobtrusive for the user, yet able to withstand the wet and dirty environments in which they must perform. Clear and prompt indication of any increase in gas monitored (or any decrease for oxygen) is of paramount importance – loud and bright alarms are effective in raising the alarm to the user.

Legislation

European Commission Directive 2017/164 established an increased list of indicative occupational exposure limit values (IOELVs). IOELV are health-based, non-binding values, derived from the most recent scientific data available and considering the availability of reliable measurement techniques. Non-binding but best practice. The list includes carbon monoxide, nitrogen monoxide, nitrogen dioxide, sulphur dioxide, hydrogen cyanide, manganese, diacetyl and many other chemicals. The list is based on Council Directive 98/24/EC that considers the protection of the health and safety of workers from the risks related to chemical agents in the workplace. For any chemical agent for which an IOELV has been set at Union level, Member States are required to establish a national occupational exposure limit value. They also are required to take into account the Union limit value, determining the nature of the national limit value in accordance with national legislation and practice. Member States will be able to benefit from a transitional period ending at the latest on 21 August 2023.

The Health and Safety Executive (HSE) state that each year several workers will suffer from at least one episode of work-related illness. Although, most illnesses are relatively mild cases of gastroenteritis, there is also a risk for potentially fatal diseases, such as leptospirosis (Weil’s disease) and hepatitis. Even though these are reported to the HSE, there could be significant under-reporting as there is often failure to recognise the link between illness and work.

Under domestic law of the Health and Safety at Work etc Act 1974, employers are responsible for ensuring the safety of their employees and others. This responsibility is reinforced by regulations.

The Confined Spaces Regulations 1997 applies where the assessment identifies risks of serious injury from work in confined spaces. These regulations contain the following key duties:

  • Avoid entry to confined spaces, e.g., by doing the work from the outside.
  • If entry to a confined space is unavoidable, follow a safe system of work.
  • Put in place adequate emergency arrangements before the work start.

The Management of Health and Safety at Work Regulations 1999 requires employers and self-employed people to carry out a suitable and sufficient assessment of the risks for all work activities for the purpose of deciding what measures are necessary for safety. For work in confined spaces this means identifying the hazards present, assessing the risks and determining what precautions to take.

Our solution

Elimination of these gas hazards is virtually impossible, so permanent workers and contractors must depend on reliable gas detection equipment to protect them. Gas detection can be provided in both fixed and portable forms. Our portable gas detectors protect people against a wide range of gas hazards, and include T4x, Clip SGD, Gasman, Tetra 3, Gas-Pro, T4 and Detective+. Our fixed gas detectors are used where reliability, dependability and lack of false alarms are instrumental to efficient and effective protection of assets and areas, and include the Xgard, Xgard Bright and IRmax product ranges. Combined with a variety of our fixed detectors, our gas detection control panels offer a flexible range of solutions that measure flammable, toxic and oxygen gases, report their presence and activate alarms or associated equipment, for the wastewater industry we often recommend our Gasmaster panel.

To find out more on the gas hazards in wastewater visit our industry page for more information.

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The Dangers of Gas Exposure in Wineries

Wineries face a unique set of challenges when it comes to safeguarding workers from the potential harm caused by hazardous gases. Gas exposure has the potential to occur at every stage of the wine production process, from the moment that the grapes arrive at the winery facility, through to the fermentation and bottling activities. Care must be taken at each stage to ensure that workers are not exposed to unnecessary risk. There are several specific environments within the winery facility that pose a risk of gas leakage and exposure, including fermentation rooms, pits, barrel cellars, sumps, storage tanks and bottling rooms. The main gas hazards that are found during the winemaking process are carbon dioxide, and oxygen displacement, but also hydrogen sulphide, sulphur dioxide, ethyl alcohol and carbon monoxide.

What are the Gas Hazards?

Hydrogen sulphide (H2S)

Hydrogen sulphide is a gas that can be present during the fermentation process. It is more commonly present in damp conditions where bacterial action has acted on natural oils. It hides dissolved in standing water until disturbed. The most dangerous occurrence is when cleaning a confined space e.g., a tank where released gases cannot easily escape. A pre-entry check comes up clean, and the standing water is then disturbed upon entry. The risks associated with H2S are that it is potentially hazardous to health, upsetting breathing patterns. Hydrogen sulphide poses severe respiratory risks, even at a relatively low concentration in the air. The gas is very easily and rapidly absorbed into the bloodstream through the lung tissue, which means it is distributed throughout the whole body very quickly.

Sulphur Dioxide (SO2)

Sulphur Dioxide is a natural by-product of fermentation, but it is also commonly used as an additive in the process of organic wine making. Extra SO2 is added during the wine making process in order to prevent the growth of any undesirable yeast and microbes within the wine. Sulphur dioxide can be highly hazardous to health and is a highly toxic gas, causing numerous irritations in the body upon contact. Sulphur dioxide is a gas that can cause irritation to the airways, nose, and throat. Workers who are exposed to high levels of sulphur dioxide may experience vomiting, nausea, stomach cramps, and irritation or corrosive damage to the lungs and airways.

Ethanol (ethyl alcohol)

Ethanol is the main alcoholic product of organic wine fermentation. It helps to maintain the flavour of the wine and stabilizes the aging process. Ethanol is created during fermentation as the yeast converts sugar from the grapes. Wine typically contains somewhere between 7% and 15% ethanol, which gives the drink its alcohol by volume (ABV) percentage. The amount of ethanol actually produced depends on the sugar content of the grapes, the fermentation temperature, and the type of yeast that is used. Ethanol is a colourless and odourless liquid that gives off flammable and potentially hazardous fumes. The fumes given off by ethanol or ethyl alcohol can irritate the airways and lungs if inhaled, with the possibility of intense coughing and choking.

Where are the dangers?

Open Fermentation Tanks

Any worker whose job involves carrying out operations over an open fermentation vessel or tank may be at a high risk of gas exposure, especially to CO2, or oxygen depletion. It has been shown that a worker who leans over the top of an open fermenter during full production, even though they may be as much as 10 feet off the ground, can potentially be exposed to 100% CO2. Therefore, particular care and attention to gas detection should be taken in these areas.

Exposure Due To Inadequate Ventilation

The fermentation process needs to take place in environments that are well ventilated to avoid the build-up of toxic and asphyxiant gases. Fermentation rooms, tank rooms, and cellars are all places that may pose a risk. During cold weather or night-time, increased levels of gas may build up as door and window vents may be shut.

Confined Spaces

Confined spaces such as pits and sumps are often problematic and well known for the potential build-up of hazardous gases. The definition of a confined space in a winery is one that contains, or may contain, a hazardous atmosphere, has the potential for engulfment by material, or an entrant to the environment may become trapped or asphyxiated.

Multiple Units

As a winery grows and expands their operations, they may want to add new production units to meet the demand. However, it is important to remember that potential gas exposure risks differ between environments, e.g., the gas risk in a fermentation cellar is not the same as a barrel room. Therefore, different types of gas detectors may be needed in different areas.

For more information about gas detection solutions for wineries, or to ask further questions get in touch today.

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Gas Hazards in Wastewater

Water is vital to our daily lives, both for personal and domestic use and industrial/commercial applications making water sites both numerous and widespread. Despite the quantity and location of water sites, only two environments predominate, and these are quite specific. They are clean water and wastewater. This blog details gas risks encountered at wastewater sites and how they may be mitigated. 

The wastewater industry is always wet, with temperatures between 4 and 20oc near the water and rarely far from that limited temperature range even away from the immediate location of the wastewater. 90%+ relative humidity, 12 +/- 8oc, atmospheric pressure, with multiple toxic and flammable gas hazards and the risk of oxygen depletion. Gas detectors must be chosen to suit the specific environment in which they operate, and whilst high humidity is generally challenging to all instrumentation, the constant pressure, moderate temperatures and narrow temperature range is a far greater benefit to safety instrumentation. 

Gas Hazards  

The main gases of concern in wastewater treatment plants are:

Hydrogen sulphide, methane and carbon dioxide are the by-products of the decomposition of organic materials that exist in the waste flows feeding the plant. The build-up of these gases may lead to the lack of oxygen, or in some cases, explosion when coupled with a source of ignition. 

Hydrogen sulphide (H2S)

Hydrogen sulphide is a common product of the biodegradation of organic matter; pockets of H2S can collect in rotting vegetation, or sewage itself, and be released when disturbed. Workers in sewerage and wastewater plants and pipework can be overcome by H2S, with fatal consequences. Its high toxicity is the main danger of H2S. Prolonged exposure to 2-5 parts per million (ppm) H2S can cause nausea and headaches and bring tears to the eyes. H2S is an anaesthetic, hence at 20ppm, symptoms include fatigue, headaches, irritability, dizziness, temporary loss of the sense of smell and impaired memory. Severity of symptoms increase with concentration as nerves shut down, through coughing, conjunctivitis, collapse and rapid unconsciousness. Exposure at higher levels can result in rapid knock down and death. Prolonged exposure to low levels of H2S may cause chronic illness or can also kill. Because of this, many gas monitors will have both instantaneous and TWA (Time-Weighted Average) alerts. 

Methane (CH4)

Methane is a colourless, highly flammable gas that is the primary component of natural gas, also referred to as biogas. It can be stored and/or transported under pressure as a liquid-gas. CH4 is a greenhouse gas that is also encountered in normal atmospheric conditions at a rate of approximately 2 parts per million (ppm). High exposure can lead to slurred speech, vision problems and memory loss. 

Oxygen (O2)

The normal concentration of oxygen in the atmosphere is approximately 20.9% volume. In the absence of adequate ventilation, the level of oxygen can be reduced surprisingly quickly by breathing and combustion processes. O2 levels may also be depleted due to dilution by other gases such as carbon dioxide (also a toxic gas), nitrogen or helium, and chemical absorption by corrosion processes and similar reactions. Oxygen sensors should be used in environments where any of these potential risks exist. When locating oxygen sensors, consideration needs to be given to the density of the diluting gas and the “breathing” zone (nose level). 

Safety Considerations 

Risk assessment

Risk assessment is critical, as you need to be aware of the environment that you are entering and thus working in. Therefore, understanding the applications and identifying the risks regarding all safety aspects. Focusing on gas monitoring, as part of the risk assessment, you need to be clear on what gases may be present. 

Fit for purpose

There is a variety of applications within the water treatment process, giving the need to monitor multiple gases, including carbon dioxide, hydrogen sulphide, chlorine, methane, oxygen, ozone and chlorine dioxide. Gas detectors are available for single or multiple gas monitoring, making them practical for different applications as well as making sure that, if conditions change (such as sludge is stirred up, causing a sudden increase in hydrogen sulphide and flammable gas levels), the worker is still protected. 

Legislation  

European Commission Directive 2017/164 issued in January 2017, established a new list of indicative occupational exposure limit values (IOELVs). IOELV are health-based, non-binding values, derived from the most recent scientific data available and considering the availability of reliable measurement techniques. The list includes carbon monoxide, nitrogen monoxide, nitrogen dioxide, sulphur dioxide, hydrogen cyanide, manganese, diacetyl and many other chemicals. The list is based on Council Directive 98/24/EC that considers the protection of the health and safety of workers from the risks related to chemical agents in the workplace. For any chemical agent for which an IOELV has been set at Union level, Member States are required to establish a national occupational exposure limit value. They also are required to take into account the Union limit value, determining the nature of the national limit value in accordance with national legislation and practice. Member States will be able to benefit from a transitional period ending at the latest on 21 August 2023. 

The Health and Safety Executive (HSE) state that each year several workers will suffer from at least one episode of work-related illness. Although, most illnesses are relatively mild cases of gastroenteritis, there is also a risk for potentially fatal diseases, such as leptospirosis (Weil’s disease) and hepatitis. Even though these are reported to the HSE, there could be significant under-reporting as there is often failure to recognise the link between illness and work. 

Our solutions  

Elimination of these gas hazards is virtually impossible, so permanent workers and contractors must depend on reliable gas detection equipment to protect them. Gas detection can be provided in both fixed and portable forms. Our portable gas detectors protect against a wide range of gas hazards, these include T4x, Clip SGD, Gasman, Tetra 3, Gas-Pro, T4 and Detective+. Our fixed gas detectors are used where reliability, dependability and lack of false alarms are instrumental to efficient and effective gas detection, these include Xgard, Xgard Bright and IRmax. Combined with a variety of our fixed detectors, our gas detection control panels offer a flexible range of solutions that measure flammable, toxic and oxygen gases, report their presence and activate alarms or associated equipment, for the wastewater industry our panels include Gasmaster.   

To find out more on the gas hazards in wastewater visit our industry page for more information. 

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What are the dangers of gas in telecommunications?

The telecommunication industry contains includes cable providers, internet service providers, satellite providers and telephone providers and confined spaces. Even simple above ground termination boxes may contain gas hazards generated from the cable runs underground. Gases such as methane, carbon dioxide and hydrogen sulphide can run through cable trunking accumulating in termination boxes and manifesting as hazards when the termination box is opened.

The risk of danger occurs when a worker is sent to carry out tasks involving opening up of enclosed volumes that may not have been accessed for a period of time. All telecommunications companies have these in abundance.

What are the Dangers?

Those working in the telecommunications industry are at risk from a variety of gaseous dangers, many of which could cause harm to their health and safety. Though less obvious, these risks should be taken as seriously as falls from heights or electrocution, and they require a similar level of training. A worker must not climb to an elevated position without a harness, similarly they shouldn’t be accessing confined spaces without appropriate confined space training. Awareness of the dangers present and minimising the risks that could lead to adverse effects is a well-known safety principle. Training and proper PPE can help protect workers from these hazards.

Gas Hazards and Risks

As there are many confined spaces in the telecommunication industry workers are at risk from the presence of hazardous and toxic gases there. Hazardous gases can also be linked to seemingly simple above-ground termination boxes. Gases such as methane, carbon dioxide and hydrogen sulphide sometimes travel through the cable trunking, and therefore, when the termination box is opened, a build-up of these gases can be released.

Enclosed or partially enclosed spaces with high levels of methane in the air reduce the amount of oxygen available to breathe and therefore can cause mood changes, speech and vision problems, memory loss, nausea, sickness, facial flushing and headaches. In more severe cases and prolonged exposure, there may be changes in breathing and heart rate, balance problems, numbness, and unconsciousness. There is also a risk of fire as methane is highly flammable.

Carbon monoxide (CO) consumption also poses serious health issues to workers, with those ingesting the toxic substance facing flu-like symptoms, chest pain, confusion, fainting arrhythmias, seizures, or even worse health effects for high or long lasting exposures. Hydrogen sulphide (H2S) poisoning causes similar issues, as well as delirium, tremors, convulsions, and skin and eye irritation. Carbon dioxide is an asphyxiant gas that can displace oxygen and hance dizziness.

Our solution

Gas detection can be provided in both fixed and portable forms. Our portable gas detectors protect against a wide range of gas hazards, these include Tetra 3 and T4. Our fixed gas detectors are used where reliability, dependability and lack of false alarms are instrumental to efficient and effective gas detection, these include Xgard and Xgard Bright. Combined with a variety of our fixed detectors, our gas detection control panels offer a flexible range of solutions which are able to measure flammable, toxic and oxygen gases, report their presence and activate alarms or associated equipment, for the telecommunication industry our panels include Gasmaster.

To find out more on the dangers of gas hazards in telecommunication visit our industry page for more information.

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Transportation and Key Gas Challenges 

The transportation sector is one of the largest industries in the world, spanning a variety of applications. The sector offers services concerned with the movement of people and cargo of all types, across air freight and logistics, airlines and airport services, road and rail, transportation infrastructure, trucking, highways, rail tracks, and marine ports and services.

Gas hazards during transportation  

The transport of dangerous goods is regulated in order to prevent, accidents involving people or property, damage to the environment. There a numerous gas hazards including the transportation of hazardous material, air conditioning emissions, cabin combustion and hangar leaks. 

The transportation of hazardous materials poses a risk to those involved. There are nine classification areas specified by the United Nations (UN) including explosives, gases, flammable liquids and solids, oxidising substances, toxic substances, radioactive materials, corrosive substances and miscellaneous goods. With the risk of an accident occurring being more likely when transporting these materials. Although the biggest cause for concern within the industry being the transportation of non-flammable non-toxic gas is asphyxiation. As a slow leak in a storage container can drain all of the oxygen in the air and cause the individuals in the environment to suffocate. 

Leaks within aircraft hangars and fuel storage areas of highly explosive aviation fuel is an area that must be monitored to prevent fires, equipment damage, and at the worst fatalities. It is essential to choose a suitable gas detection solution that focuses on the aircraft rather than the aircraft hangar, avoids false alarms, and can monitor large areas. 

Not only is it the external environment that faces gas risks in transportation, those working in the sector also face similar challenges. Air conditioning emissions poses a gas hazard threat due to the burning of fossil fuels leading to a subsequent emission of carbon monoxide (CO). high levels of CO in a confined area such as a vehicle cabin, of more than the normal level (30ppm) or an oxygen level below normal (19%) can result in dizziness, feeling and being sick, tiredness and confusion, stomach pain, shortness of breath and difficulty breathing. Therefore, proper ventilation in these spaces with the assistance of a gas detector is paramount to ensuring the safe of those working in the transportation industry. 

Similarly, in the air sector cabin combustion and fuselage fires, in the central portion of an airplane, poses a real threat. Although flame retardant materials are applied, if a fire does start the cabin’s trim and fittings can still generate toxic gases and vapours that could be more dangerous than the fire itself. Inhalation of harmful gases caused by a fire in these environments tend to be the main direct cause of fatalities.

Transportation Standards and Certifications 

Each mode of transport, (road, rail, air, sea and inland waterway) has its own regulations but they are generally harmonized with the United Nations Economic Commission for Europe (UNECE). The Hazardous Materials Transportation Act (HMTA), enacted in the USA in 1975, states that regardless of the type of transportation, any company whose goods fall into one of the nine categories specified as hazardous by the UN, must comply with the regulations or risk fines and penalties. 

Those working in the transport sector in the UK must comply with the requirements laid out in the UN Model Regulations which assigns each dangerous substance or article a specific class that correlates how dangerous it is. It does this via the packing group (PG) classification, according to PG I, PG II or PG III. 

From an European standpoint the International Carriage of Dangerous Goods by Road (ADR) governs the regulations on how to classify, pack, label and certify dangerous goods. It also comprises vehicle and tank requirements and other operational requirements. The Carriage of Dangerous Goods and Use of Transportable Pressure Equipment Regulations (2009) also is relevant in England, Wales and Scotland. 

Other relevant regulations include the International Carriage of Dangerous Goods by Inland Navigation (ADN), the International Maritime Dangerous Goods (IMDG) and The International Civil Aviation Organization’s (ICAO) Technical Instruction.

Our solution 

Gas detection can be provided in both fixed and portable forms. Our portable gas detectors protect against a wide range of gas hazards, these include T4x, Clip SGD, Gasman, Tetra 3, Gas-pro, and T4. Our fixed gas detectors are used where reliability, dependability and lack of false alarms are instrumental to efficient and effective gas detection, these include Xgard, Xgard Bright, and IRmax. Combined with a variety of our fixed detectors, our gas detection control panels offer a flexible range of solutions which are able to measure flammable, toxic and oxygen gases, report their presence and activate alarms or associated equipment, for the transportation industry our panels include Gasmaster and Vortex.  

To find out more on the dangers of gas hazards in transportation visit our industry page for more information.  

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Detecting dangers in dairy: What gases should you be aware of? 

Global demand for dairy continues to increase in large part due to population growth, rising incomes and urbanisation. Millions of farmers worldwide tend approximately 270 million dairy cows to produce milk. Throughout the dairy farm industry there are a variety of gas hazards that pose a risk to those working in the dairy industry.  

What are the dangers workers face in the dairy industry?

Chemicals

Throughout the dairy farm industry, chemicals are used for variety of tasks including cleaning, applying various treatments such as vaccinations or medications, antibiotics, sterilising and spraying. If these chemicals and hazardous substances are not used or stored correctly, this can result in serious harm to the worker or the surrounding environment. Not only can these chemicals cause illness, but there is also a risk of death if a person is exposed. Some chemicals can be flammable and explosive whilst others are corrosive and poisonous. 

There are several ways to manage these chemical hazards, although the main concern should be in implementing a process and procedure. This procedure should ensure all staff are trained in the safe use of chemicals with records being maintained. As part of the chemical procedure, this should include a chemical manifest for tracking purposes. This type of inventory management allows for all personal to have access to Safety Data Sheets (SDS) as well as usage and location records. Alongside this manifest, there should be consideration for the review of current operation.  

  • What is the current procedure?  
  • What PPE is required?  
  • What is the process for discarding out of date chemicals and is there is a substitute chemical that could pose less of a risk to your workers? 

Confined Spaces

There are numerous circumstances that could require a worker to enter a confined space, including feed silos, milk vats, water tanks and pits in the dairy industry. The safest way to eliminate a confined space hazard, as mentioned by many industry bodies, is to employ a safe design. This will include the removal of any need to enter a confined space. Although, this may not be realistic and from time to time, cleaning routines need to take place, or a blockage may occur, however, there is a requirement to ensure there is the correct procedures to address the hazard. 

Chemical agents when used in a confined space can increase the risk of suffocation with gases pushing out oxygen. One way you can eliminate this risk is by cleaning the vat from the outside using a high-pressure hose. If a worker does need to enter the confined space, check that the correct signage is in place since entry and exit points will be restricted. You should consider isolation switches and check that your staff understand the correct emergency rescue procedure if something were to happen. 

Gas Hazards

Ammonia (NH3) is found in animal waste and slurry spreading on farming and agricultural land. It is characteristically a colourless gas with a pungent smell that arises through the decomposition of nitrogen compounds in animal waste. Not only is it harmful to human health but also harmful to livestock wellbeing, due to its ability to cause respiratory diseases in livestock, and eye irritation, blindness, lung damage, alongside nose and throat damage and even death in humans. Ventilation is a key requirement in preventing health issues, as poor ventilation heightens the damage caused by this gas.  

Carbon dioxide (CO2) is naturally produced in the atmosphere; although, levels are increased through farming and agricultural processes. CO2, is colourless, odourless, and is emitted from agricultural equipment, crop and livestock production and other farming processes. CO2 can congregate areas, such as waste tanks and silos. This results in oxygen in the air to be displaced and increasing the risk of suffocation for animals and humans.  Sealed silos, waste and grain storage spaces are specifically dangerous as CO2 can accumulate here and lead to them being unsuitable for humans without an external air supply. 

Nitrogen dioxide (NO2) is one of a group of highly reactive gases known as oxides of nitrogen or nitrogen oxides (NOx). At worst, it can cause sudden death when consumed even from short term exposure. This gas can cause suffocation and is emitted from silos following specific chemical reactions of plant material. It is recognisable by its bleach-like smell and its properties tend to create a red-brown haze. As it gathers above certain surfaces it can run into areas with livestock through silo chutes, and therefore poses a real danger to humans and animals in the surrounding area. It can also affect lung function, cause internal bleeding, and ongoing respiratory problems. 

When should gas detectors be used?

Gas detectors provide added value anywhere on dairy farms and around slurry silos, but above all: 

  • When and where slurry is being mixed 
  • During pumping and bringing out slurry
  • On and around the tractor during slurry mixing or spreading 
  • In the stable during maintenance work on slurry pumps, slurry scrapers and the like 
  • Near and around small openings and cracks in the floor, e.g., around milking robots 
  • Low to the ground in poorly ventilated corners and spaces (H2S is heavier than air and sinks to the floor) 
  • In slurry silos 
  • In slurry tanks 

Products that can help to protect yourself 

Gas detection can be provided in both fixed and portable forms. Installation of a fixed gas detector can benefit a larger space to provide continuous area and staff protection 24 hours a day. However, a portable detector can be more suited for worker’s safety. 

To find out more on the dangers in agriculture and farming, visit our industry page for more information. 

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Did you know about the Sprint Pro Tightness Tester?

Pressure testing is all in a day’s work for many gas engineers, but the right equipment can make all the difference.  

Did you know that you can use the Sprint Pro flue gas analyser to carry out tightness testing, with no need for additional U gauges or other bulky equipment? In this post we’ll explore how and why you can tightness test with the Sprint Pro. 

What is tightness testing? 

Tightness testing is a type of pressure test, applied to a gas supply system at the meter. Other forms of pressure testing include the let-by test (which checks for leaks in the emergency control valve [ECV]), temperature stabilisation test, standing pressure at the meter test (a measurement of the gas when it’s stationary), and working/operating pressure at the meter test (which assesses the flow and pressure of gas when appliances are being used). 

Tightness testing measures the pressure in gas pipes, in order to find evidence of leaks. A tightness test is generally carried out after a let-by test and temperature stabilisation test. The tightness test is sometimes followed by a purge and then a standing pressure test, followed by a working/operating pressure at the meter test. This allows the engineer to make a full assessment of the system.  

Using the Sprint Pro to conduct a tightness test 

All Sprint Pro models except the Sprint Pro 1 can be used to tightness test. To begin, go into the pressure menu and select let-by/tightness. You will need to attach the pipe and matching pressure relief valve to the Sprint Pro’s positive pressure inlet – the valve makes setting the desired pressure, and adjusting it if required, very easy.  

As you scroll through the Sprint Pro’s pressure menu, you’ll find that tightness testing follows let-by testing and temperature stabilisation. Full instructions for tightness testing are given in the Sprint Pro manual (click here for a PDF version).  

It is very important to note that the parameters for tightness testing, and any increases/drops in pressure that are permitted, depend on many variables, such as the age and size of the pipework, whether appliances are attached and several others. Ultimately, you as the engineer must decide whether to pass or fail the tightness test when the analyser displays the results. 

Once the test is completed, you can either print the results immediately (although this erases them from the system) or save them to the log (and they can always be printed from there). Alternatively, if you have the Sprint Mobile/Crowcon HVAC Companion app, you can Bluetooth directly to your tablet or smartphone. 

Why use a Sprint Pro for tightness testing? 

Using a Sprint Pro for pressure testing means less to carry around (no bulky water gauges, for example) and the clarity of results displayed digitally. The Sprint Pro also creates an audit trail in the form of digital logs, which can provide great peace of mind in case of any dispute or query.

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The Benefits of MPS Sensors 

Developed by NevadaNano, Molecular Property Spectrometer™ (MPS™) sensors represent the new generation of flammable gas detectors. MPS™ can quickly detect over 15 characterised flammable gases at once. Until recently, anyone who needed to monitor flammable gases had to select either a traditional flammable gas detector containing a pellistor sensor calibrated for a specific gas, or containing an infra-red (IR) sensor which also varies in output according to the flammable gas being measured, and hence needs to be calibrated for each gas. While these remain beneficial solutions, they are not always ideal. For example, both sensor types require regular calibration and the catalytic pellistor sensors also need frequent bump testing to ensure they have not been damaged by contaminants (known as ‘sensor poisoning’ agents) or by harsh conditions. In some environments, sensors must frequently be changed, which is costly in terms of both money and downtime, or product availability. IR technology cannot detect hydrogen – which has no IR signature, and both IR and pellistor detectors sometimes incidentally detect other (i.e., non-calibrated) gases, giving inaccurate readings that may trigger false alarms or concern operators. 

The MPS™ sensor delivers key features that provide real world tangible benefits to operator and hence workers. These include: 

No calibration  

When implementing a system containing a fixed head detector, it is common practice to service on a recommended schedule defined by manufacturer. This entails ongoing regular costs as well potentially disrupting production or process in order service or even gain access to detector or multiple detectors. There may also be a risk to personnel when detectors are mounted in particularly hazardous environments. Interaction with an MPS sensor is less stringent because there are no unrevealed failure modes, provided air is present. It would be wrong to say there is no calibration requirement. One factory calibration, followed by a gas test when commissioning is sufficient, because there is an internal automated calibration being performed every 2 seconds throughout the working life of the sensor. What is really meant is – no customer calibration. 

The Xgard Bright with MPS™ sensor technology does not require calibration. This in turn reduces the interaction with the detector resulting in a lower total cost of ownership over the sensor life cycle and reduced risk to personnel and production output to complete regular maintenance. It is still advisable to check the cleanliness of the gas detector from time to time, since gas can’t get through thick build ups of obstructive material and wouldn’t then reach the sensor. 

Multi species gas – ‘True LEL’™  

Many industries and applications use or have as a by-product multiple gases within the same environment. This can be challenging for traditional sensor technology which can detect only a single gas that they were calibrated for at the correct level and can result in inaccurate reading and even false alarms which can halt process or production if another flammable gas type is present. The lack of response or over response frequently faced in multi gas environments can be frustrating and counterproductive compromising safety of best user practices. The MPS™ sensor can accurately detect multiple gases at once and instantly identify gas type. Additionally, the MPS™ sensor has a on board environmental compensation and does not require an externally applied correctional factor. Inaccurate readings and false alarms are a thing of the past.  

No sensor poisoning  

In certain environments traditional sensor types can be under risk of poisoning. Extreme pressure, temperature, and humidity all have the potential to damage sensors whist environmental toxins and contaminants can ‘poison’ sensors, leading to severely compromised performance. Detectors in environments where poisons or inhibitors may be encountered, regular and frequent testing is the only way to ensure that performance is not being degraded. Sensor failure due to poisoning can be a 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. Additionally, the MPS sensor is not harmed by elevated flammable gas concentrations, which may cause cracking in conventional catalytic sensor types for example. The MPS sensor carries on working. 

Hydrogen (H2)

The usage of Hydrogen in industrial processes is increasing as the focus to find a cleaner alternative to natural gas usage. Detection of Hydrogen is currently restricted to pellistor, metal oxide semiconductor, electrochemical and less accurate thermal conductivity sensor technology due to Infra-Red sensors inability to detect Hydrogen. When faced with challenges highlighted above in poisoning or false alarms, the current solution can leave operator with frequent bump testing and servicing in addition to false alarm challenges. The MPS™ sensor provides a far better solution for Hydrogen detection, removing the challenges faced with traditional sensor technology. A long-life, relatively fast responding hydrogen sensor that does not require calibration throughout the life cycle of the sensor, without the risk of poisoning or false alarms, can significantly save on total cost of ownership and reduces interaction with unit resulting in peace of mind and reduced risk for operators leveraging MPS™ technology. All of this is possible thanks to MPS™ technology, which is the biggest breakthrough in gas detection for several decades. The Gasman with MPS is hydrogen (H2) ready. A single MPS sensor accurately detects hydrogen and common hydrocarbons in a fail-safe, poison-resistant solution without recalibration.

For more on Crowcon, visit https://www.crowcon.com or for more on MPSTM visit https://www.crowcon.com/mpsinfixed/  

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Carbon Dioxide: What are the dangers in the Food and Beverage Industry? 

Almost all industries must monitor gas hazards, with the food and beverage industry no exception. Although, there is a lack of awareness regarding the dangers of carbon dioxide (CO2) and the dangers those working in the industry face. CO2 is the most common gas in the food and beverage industry because it is used in the carbonation of drinks, to propel beverages to the tap in pubs and restaurants and to keep food items cold during transportation in the form of dry ice. It is also naturally produced in beverage manufacturing processes by leavening agents like yeast and sugar. Although CO2 may seem harmless at first glance as we exhale it with every breath, and plants need it for survival, the presence of carbon dioxide becomes a problem when its concentration rises to dangerous levels.

The Dangers of CO2

Carbon dioxide occurs naturally in the atmosphere (typically 0.04% in air). CO2 is colourless and odourless, heavier than air, and tends to sink to the floor. CO2 collects in cellars and at the bottom of containers and confined spaces such as tanks or silos.

Since CO2 is heavier than air, it quickly displaces oxygen at high concentrations can result in asphyxiation due to a lack of oxygen or breathable air. Exposure to CO2 is easy, especially in a confined space like a tank or a cellar. Early symptoms of exposure to high levels of carbon dioxide include dizziness, headaches, and confusion, followed by loss of consciousness. Accidents and fatalities occur in the food and beverage industry due to a carbon dioxide leak. Without proper detection methods and processes in place, everyone at a facility could be at risk.

Gas Monitors – what are the benefits?

Any application that uses carbon dioxide puts workers at risk, and the only way to identify high levels before it’s too late is to use gas monitors.

Gas detection can be provided in both fixed and portable forms. Installation of a fixed gas detector can benefit a larger space such as plant rooms to provide continuous area and staff protection 24 hours a day. However, a portable detector can be more suited for worker safety in and around the cylinder storage area and in spaces designated as a confined space. This is especially true for pubs and beverage dispensing outlets for the safety of workers and those unfamiliar with the environment, such as delivery drivers, sales teams or equipment technicians. The portable unit can easily be clipped to clothing and will detect pockets of CO2 using alarms and visual signals, indicating that the user should immediately vacate the area.

Personal gas detectors continuously monitor the air in workers’ breathing zone when worn correctly,  to give them better awareness and the information they need to make smart decisions in the face of danger. Not only can gas monitors detect carbon dioxide in the air, but they can also alert others if an employee is in danger. Carbon dioxide can be monitored using a single gas monitor or by using a multi-gas monitor with a dedicated carbon dioxide sensor. It is important to note the carbon dioxide can escalate to dangerous levels before an oxygen sensor would alarm.

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