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GasBook Honeywell Gas Detection 1 Introduction The Gas Book is intended to offer a simple guide to anyone considering the use of fixed and portable gas detection equipment. The aim has been to provide a complete and comprehensive introduction to the subject– from detailing the principles of detection that different devices employ to providing information on certifications and application suitability. A diverse variety of applications n most industries, one of the key parts of any safety plan for reducing and processes increasingly involve risks to personnel and plant is the use of early warning devices such as gas detectors. These can help to provide more time in which to take the use and manufacture of highly I remedial or protective action. They can also be used as part of a total, dangerous substances, particularly integrated monitoring and safety system which may include various other safety aspects including fire detection and emergency process shutdown. flammable, toxic and Oxygen gases. Gas detection can be divided into two overriding categories; fixed gas Inevitably, occasional escapes of detection and portable gas detection. As the name might suggest, fixed gas detection represents a static type of detection system for flammable, toxic gas occur, which create a potential and Oxygen gas hazards and is designed to monitor processes, and protect hazard to the industrial plants, their plant and assets as well as personnel on-site. employees and people living nearby. Portable gas detection is designed specifically to protect personnel from Worldwide incidents, involving the threat of flammable, toxic or Oxygen gas hazards and is typically a small device worn by an operator to monitor the breathing zone. Many sites asphyxiation, explosions and loss of incorporate a mix of both fixed and portable gas detection as part of their life, are a constant reminder of this safety philosophy, but the suitability of which type to use will depend on problem. several factors, including how often the area is accessed by personnel. 2 www.honeywellanalytics.com / www.gasmonitors.com Contents Section Subject Page Section Subject Page 1 Introduction 2 18 ATEX 80-81 2 Honeywell Gas Detection brands 4-5 IEC Standards 82-83 Equipment markings 84-85 3 What is gas? 6 19 Area classification 86-87 4 Gas hazards 7 20 Apparatus design 88-89 5 Flammable gas hazards 8 Flammable limit 9 21 Apparatus classification 90-91 Flammable gas properties 10-11 22 Ingress protection of enclosures 92-93 Flammable gases data 12-19 23 Safety integrity levels (SIL) 94-95 6 Toxic gas hazards 20 24 Gas detection systems 96-97 Workplace exposure limits 21 Location of sensors 98-99 Toxic exposure limits 22-25 Typical sensor mounting options 100 Toxic gases data 26-29 Typical system configurations 100-101 7 Asphyxiant (Oxygen deficiency) hazard 30 25 Installation 102 8 Oxygen enrichment 31 26 Gas detection maintenance and ongoing care 106-109 9 Typical areas that require gas detection 32-35 27 Glossary 110-113 10 Principles of detection 36 Combustible gas sensor 36 Catalytic sensor 36 Speed of response 37 Sensor output 37 Calibration 38 Infrared gas detector 39 Open path flammable infrared gas detector 40 Electrochemical cell sensors 41 Photo Ionised Detection (PID) 42 Chemcassette® sensor 42 Comparison of gas detection techniques 43 11 Selecting gas detection 44-45 12 Maximising time and efficiency 46-47 13 Communications protocols 48-49 14 Fixed gas detection from Honeywell 50-51 15 Portable gas detectors 52 Why are portable gas detectors so important? 54 Breathing zone 55 Typical gases requiring portable detection 55 Portable gas detector types 56 Operational modes of a gas detector 56 Features and functionality 57 Accessories 58 Alarms and status indication 59 Typical applications for portable gas detectors 60 Confined spaces 60-61 Marine 62 Water treatment industry 63 Military 64-65 Hazardous Material (HAZMAT) emergency response 66 Oil and gas (on and offshore) 67 PID Information 68 Measuring Solvent, Fuel and VOC Vapour in the workplace environment 68-71 Maintaining portable gas detection 72 Reducing the cost of device testing 73 How to perform a manual bump test 73 Portable gas detectors from Honeywell 74-75 16 North American hazardous area standards and approvals 76 North American Ex marking and area classification 77 17 European hazardous area standards and approvals 78-79 3 2 Honeywell Gas Detection brands At Honeywell Analytics our key focus is our customers. We believe that the evolution of gas detection should be driven by the people using our equipment, rather than engineers deciding the needs of industry. With this in mind, we listen to what our customers want, refine our solutions to meet changing demands and we grow as our customers grow to ensure we are able to provide an added value service that meets individual requirements. Working with Industry… since the birth of gas detection ith 50 years experience in the industry, we have been Our Technical Support Centre and Product Application and Training influential in gas detection since the very beginning. Specialists, field engineers and in-house engineering support represent Many of our historic products set new benchmarks some of the very best the industry has to offer, providing over 1,100 W for gas detection in terms of performance, ease of years cumulative expertise, allowing us to deliver local business use and innovation. Today, our product lines have evolved to meet support on a corporate scale. the requirements of diverse industries and applications, delivering comprehensive solutions designed to drive down the cost of gas detection, whilst providing enhanced safety. 4 www.honeywellanalytics.com / www.gasmonitors.com Honeywell Gas Detection brands GAS FACT The word gas was coined in 1650–60 by J. B. van Helmont (1577–1644), a Flemish chemist. It comes from the Greek word for chaos. W Technologies by Honeywell is a World leader in the gas Delivering value added solutions at detection industry with a strong commitment to providing affordable prices for 25 years customers with high performance, dependable portable products that are backed up by exceptional customer B BW Technologies by Honeywell was originally established in 1987 service and ongoing support. in Calgary, Canada. Over the last 25 years, we have been bringing innovative gas detection solutions to market that add value, enhance We design, manufacture and market innovative portable gas detection safety and help to reduce the ongoing cost of portable gas detection. solutions for a wide variety of applications and industries, with options to suit all budgets and hazard monitoring requirements. With offices all over the World, and a diverse and talented team of industry experts on hand to provide support to customers, we offer a Our comprehensive range includes options from single gas units that large corporate infrastructure supported by locally focused teams that require no ongoing maintenance, to feature-rich multi-gas devices that have a unique understanding of industry and applications as well as deliver additional value-added functionality. regional needs. As a leading expert in the field of portable gas detection, we provide customised on-site/field based training to meet specific customer needs and application support to assist customers with the selection and integration of solutions that are entirely fit for purpose. When it comes to device care, we also offer cost-effective benchmark support and maintenance through our comprehensive approved partner network. 5 Vehicle engines combust fuel and Oxygen and 3 What is produce exhaust gases that include Nitrogen Oxides, Carbon Monoxide and Gas? Carbon Dioxide. The name gas comes from the word chaos. Gas is a swarm of molecules moving randomly and chaotically, constantly colliding with each other and anything else around them. Gases fill any available volume and due to the very high speed at which they move will mix rapidly into any atmosphere in which they are released. Different gases are all around us in everyday life. The air we breathe is made up of several different gases including Oxygen and Nitrogen. Air Composition The table gives the Name Symbol Percent by Volume sea-level composition Nitrogen N2 78.084% of air (in Oxygen O2 20.9476% percent by volume at the Argon Ar 0.934% temperature of Carbon Dioxide CO2 0.0314% 15°C and the pressure of Neon Ne 0.001818% 101325 Pa). Methane CH4 0.0002% Helium He 0.000524% Krypton Kr 0.000114% Hydrogen H2 0.00005% Xenon Xe 0.0000087% 6 www.honeywellanalytics.com / www.gasmonitors.com 4 Gas Hazards There are three main types of gas hazard: Gases can be lighter, Flammable heavier or about the same RISK OF FIRE density as air. Gases can have an odour or AND/OR EXPLOSION be odourless. Gases e.g. can have colour or be Methane, colourless. If you can’t Butane, Propane see it, smell it or touch it, it doesn’t mean that it is not there. Toxic RISK OF POISONING e.g. Carbon Monoxide, Hydrogen, Chlorine Asphyxiant RISK OF SUFFOCATION e.g. Oxygen deficiency. Oxygen can be consumed or displaced by another gas Natural Gas (Methane) is used in many homes for heating and cooking. ! 7 5 Flammable Gas Hazards Combustion is a fairly simple chemical reaction in which The Fire Oxygen is combined rapidly Triangle with another substance The process of combustion can be resulting in the release of represented by the well known fire triangle. energy. This energy appears Three factors are always needed to cause combustion: mainly as heat – sometimes in the form of flames. A SOURCE OF The igniting substance is 1 IGNITION normally, but not always, a Hydrocarbon compound and OXYGEN can be solid, liquid, vapour 2 or gas. However, only gases FUEL IN THE FORM and vapours are considered 3 OF A GAS in this publication.
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