Ha Gas Book 2014 - 06 - 13 v5 PDF

GasBook
Honeywell Gas Detection

1 Introduction
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A diverse variety of applications
I
n most industries, one of the key parts of any safety plan for reducing
risks to personnel and plant is the use of early warning devices such
and processes increasingly involve as gas detectors. These can help to provide more time in which to take
the use and manufacture of highly 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
several factors, including how often the area is accessed by personnel.
problem.
2 www.honeywellanalytics.com
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 care106-109
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
W
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
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
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.
Delivering value added solutions at
B
W Technologies by Honeywell is a World leader in the gas
detection industry with a strong commitment to providing
customers with high performance, dependable portable
affordable prices for 25 years
products that are backed up by exceptional customer
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
3 What is
Vehicle engines
combust fuel
and Oxygen and
produce exhaust
Gas?
gases that
include Nitrogen
Oxides, Carbon
Monoxide and
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%
temperatureof 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%
4 Gas
Hazards
There are three main
types of gas hazard:
Gases can be lighter,

Flammable
heavier or about the same
density as air. Gases
RISK OF FIRE
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
1
in the form of flames. A SOURCE OF
The igniting substance is IGNITION
normally, but not always, a
2
Hydrocarbon compound and OXYGEN
can be solid, liquid, vapour
or gas. However, only gases
and vapours are considered
in this publication.
3 FUEL IN THE FORM
OF A GAS
OR VAPOUR
(N.B. The terms In any fire protection system,
‘flammable’, ‘explosive’,
and ‘combustible’ therefore, the aim is to always
are, for the purpose remove at least one of these three
of this publication, potentially hazardous items.
interchangeable).
HE
AIR
FIRE
AT
FUEL
Flammable Limit GAS
There is only a limited band of gas/air concentration which
will produce a combustible mixture. This band is specific FACT
High levels of O2 increase
for each gas and vapour and is bounded by an upper level, the flammability of materials
known as the Upper Explosive Limit (or the UEL) and a and gases – at levels such
as 24%, items such as
lower level, called the Lower Explosive Limit (LEL). clothing can spontaneously
combust!
Limits of Flammability
100% v/v gas
0% v/v air
TOO RICH
UEL
(upper explosive limit)
FLAMMABLE
RANGE
LEL
(lower explosive limit)
TOO LEAN
0% v/v gas
100% v/v air
A
t levels below the LEL, there is An increase in pressure, temperature or of less than 50% of the LEL value, so that an
insufficient gas to produce an Oxygen content will generally broaden the adequate safety margin is provided.
explosion i.e. the mixture is too flammability range.
‘lean’, whilst above the UEL, However, it should always be remembered
the mixture has insufficient Oxygen i.e. the In the average industrial plant, there would that in enclosed or unventilated areas, a
mixture is too ‘rich’. The flammable range normally be no gases leaking into the concentration in excess of the UEL can
therefore falls between the limits of the LEL surrounding area or, at worst, only a low sometimes occur. At times of inspection,
and UEL for each individual gas or mixture of background level of gas present. Therefore the special care needs to be taken when operating
gases. Outside these limits, the mixture is not detecting and early warning system will only hatches or doors, since the ingress of air from
capable of combustion. The Flammable Gases be required to detect levels from 0% of outside can dilute the gases to a hazardous,
Data on page 12 indicates the limiting values gas up to the lower explosive limit. By the combustible mixture.
for some of the better-known combustible time this concentration is reached,
gases and compounds. The data is given for shut-down procedures or site clearance (N.B LEL/LFL and UEL/UFL are, for the purpose of this
publication, interchangeable).
gases and vapours at normal conditions of should have been put into operation. In fact
pressure and temperature. this will typically take place at a concentration
9
Flammable Gas
Properties
Ignition Temperature
Flammable gases also have a temperature where ignition
will take place, even without an external ignition source
such as a spark or flame. This temperature is called the
Ignition Temperature. Apparatus for use in a hazardous
area must not have a surface temperature that exceeds the
Ignition Temperature. Apparatus is therefore marked with a
maximum surface temperature or T rating.
FLASH POINT (F.P. °C)

The flash point of a flammable liquid is the lowest temperature at which the surface of the
liquid emits sufficient vapour to be ignited by a small flame. Do not confuse this with Ignition
Temperature as the two can be very different:
Gas / Vapour Flash Point °C Ignition Temp. °C

Methane <-188 595
Kerosene 38 210
Bitumen 270 310
To convert a Celsius temperature into Fahrenheit: Tf = ((9/5)*Tc)+32 E.g. to convert -20 Celsius into Fahrenheit, first multiply the Celsius
temperature reading by nine-fifths to get -36. Then add 32 to get -4°F.
VAPOUR DENSITY
Helps determine sensor placement
The density of a gas/vapour is compared with air
When air = 1.0:
Vapour density < 1.0 will rise
Vapour density > 1.0 will fall
Gas/Vapour Vapour Density

Methane 0.55
Carbon Monoxide 0.97
Hydrogen Sulphide 1.45
Petrol Vapour 3.0 approx
GAS
FACT
It’s not just gas that holds
a potential threat - dust
can also be explosive!
Examples of explosive
dusts include polystyrene,
cornstarch and iron.
11
11
Flammable Gases Data
Molecular Boiling Relative
Common Name CAS Number Formula Weight Point °C Vapourisation Density
Acetaldehyde 75-07-0 CH3CHO 44.05 20 1.52
Acetic acid 64-19-7 CH3COOH 60.05 118 2.07
Acetic anhydride 108-24-7 (CH3CO)2O 102.09 140 3.52
Acetone 67-64-1 (CH3)2CO 58.08 56 2.00
Acetonitrile 75-05-8 CH3CN 41.05 82 1.42
Acetyl chloride 75-36-5 CH3COCl 78.5 51 2.70
Acetylene 74-86-2 CH=CH 26 -84 0.90
Acetyl fluoride 557-99-3 CH3COF 62.04 20 2.14
Acrylaldehyde 107-02-8 CH2=CHCHO 56.06 53 1.93
Acrylic acid 79-10-7 CH2=CHCOOH 72.06 139 2.48
Acrylonitrile 107-13-1 CH2=CHCN 53.1 77 1.83
Acryloyl chloride 814-68-6 CH2CHCOCl 90.51 72 3.12
Allyl acetate 591-87-7 CH2=CHCH2OOCCH3 100.12 103 3.45
Allyl alcohol 107-18-6 CH2=CHCH2CH 58.08 96 2.00
Allyl chloride 107-05-1 CH2=CHCH2Cl 76.52 45 2.64
Ammonia 7664-41-7 NH3 17 -33 0.59
Aniline 62-53-3 C6H6NH2 93.1 184 3.22
Benzaldehyde 100-52-7 C6H5CHO 106.12 179 3.66
Benzene 71-43-2 C6H6 78.1 80 2.70
1-Bromobutane 109-65-9 CH3(CH2)2CH2Br 137.02 102 4.72
Bromoethane 74-96-4 CH3CH2Br 108.97 38 3.75
1,3 Butadiene 106-99-0 CH2=CHCH=CH2 54.09 -4.5 1.87
Butane 106-97-8 C4H10 58.1 -1 2.05
Isobutane 75-28-5 (CH3)2CHCH3 58.12 -12 2.00
Butan-1-ol 71-36-3 CH3(CH2)2CH2OH 74.12 116 2.55
Butanone 78-93-3 CH3CH2COCH3 72.1 80 2.48
But-1-ene 106-98-9 CH2=CHCH2CH3 56.11 -6.3 1.95
But-2-ene (isomer not stated) 107-01-7 CH3CH=CHCH3 56.11 1 1.94
Butyl acetate 123-86-4 CH3COOCH2(CH2)2CH3 116.2 127 4.01
n-Butyl acrylate 141-32-2 CH2=CHCOOC4H9 128.17 145 4.41
Butylamine 109-73-9 CH3(CH2)3NH2 73.14 78 2.52
Isobutylamine 78-81-9 (CH3)2CHCH2NH2 73.14 64 2.52
Isobutylisobutyrate 97-85-8 (CH3)2CHCOOCH2CH(CH3)2 144.21 145 4.93
Butylmethacrylate 97-88-1 CH2=C(CH3)COO(CH2)3CH3 142.2 160 4.90
Tert-butyl methyl ether 1634-04-4 CH3OC(CH3)2 88.15 55 3.03
n-Butylpropionate 590-01-2 C2H5COOC4H9 130.18 145 4.48
Butyraldehyde 123-72-8 CH3CH2CH2CHO 72.1 75 2.48
Isobutyraldehyde 78-84-2 (CH3)2CHCHO 72.11 63 2.48
Carbon disulphide 75-15-0 CS2 76.1 46 2.64
Carbon monoxide 630-08-0 CO 28 -191 0.97
Carbonyl sulphide 463-58-1 COS 60.08 -50 2.07
Chlorobenzene 108-90-7 C6H5Cl 112.6 132 3.88
1-Chlorobutane 109-69-3 CH3(CH2)2CH2Cl 92.57 78 3.20
2-Chlorobutane 78-86-4 CH3CHClC2H5 92.57 68 3.19
1-Chloro-2,3-epoxypropane 106-89-8 OCH2CHCH2Cl 92.52 115 3.30
Chloroethane 75-00-3 CH3CH2Cl 64.5 12 2.22
2-Chloroethanol 107-07-3 CH2ClCH2OH 80.51 129 2.78
Chloroethylene 75-01-4 CH2=CHCl 62.3 -15 2.15
Chloromethane 74-87-3 CH3Cl 50.5 -24 1.78
1-Chloro-2-methylpropane 513-36-0 (CH3)2CHCH2Cl 92.57 68 3.19
3-Chloro-2-methylprop-1-ene 563-47-3 CH2=C(CH3)CH2Cl 90.55 71 3.12
5-Chloropentan-2-one 5891-21-4 CH3CO(CH2)3Cl 120.58 71 4.16
1-Chloropropane 540-54-5 CH3CH2CH2Cl 78.54 37 2.70
2-Chloropropane 75-29-6 (CH3)2CHCl 78.54 47 2.70
Chlorotrifluoroethyl-ene 79-38-9 CF2=CFCl 116.47 -28.4 4.01
-
-Chlorotoluene 100-44-7 C6H5CH2Cl 126.58 4.36
References: BS EN 60079-20-1 (supersedes 61779) Electrical apparatus for the detection and
measurement of flammable gases-Part 1: General requirements and test methods. NIST Chemistry Web
Book June 2005 release. Aldrich Handbook of Fine Chemicals and Laboratory Equipment 2003-2004.
Data may change by country
and date, always refer to local Please note: Where “gas” is stated under Flash Point (F.P. C°), the compound is always in a gaseous state
up-to-date regulations. and therefore does not have a FP.
Flammable Limits
F.P. °C LFL % v/v UFL % v/v LFL mg/L UFL mg/L I.T. °C
–38 4.00 60.00 74 1,108 204
40 4.00 17.00 100 428 464
49 2.00 10.30 85 428 334
<–20 2.50 13.00 80 316 535
2 3.00 16.00 51 275 523
–4 5.00 19.00 157 620 390
gas 2.30 100.00 24 1,092 305
<–17 5.60 19.90 142 505 434
–18 2.80 31.80 65 728 217
56 2.90 85 406
–5 2.80 28.00 64 620 480
–8 2.68 18.00 220 662 463
13 1.70 10.10 69 420 348
21 2.50 18.00 61 438 378
–32 2.90 11.20 92 357 390
gas 15.00 33.60 107 240 630
75 1.20 11.00 47 425 630
64 1.40 62 192
–11 1.20 8.60 39 280 560
13 2.50 6.60 143 380 265
<–20 6.70 11.30 306 517 511
gas 1.40 16.30 31 365 430
gas 1.40 9.30 33 225 372
gas 1.30 9.80 31 236 460
29 1.40 12.00 52 372 359
–9 1.50 13.40 45 402 404
gas 1.40 10.00 38 235 440
gas 1.60 10.00 40 228 325
22 1.20 8.50 58 408 370
38 1.20 9.90 63 425 268
–12 1.70 9.80 49 286 312
–20 1.47 10.80 44 330 374
34 0.80 47 424
53 1.00 6.80 58 395 289
–27 1.50 8.40 54 310 385
40 1.00 7.70 53 409 389
–16 1.80 12.50 54 378 191
–22 1.60 11.00 47 320 176
–30 0.60 60.00 19 1,900 95
gas 10.90 74.00 126 870 805
gas 6.50 28.50 100 700 209
28 1.30 11.00 60 520 637
–12 1.80 10.00 69 386 250
<–18 2.00 8.80 77 339 368
28 2.30 34.40 86 1,325 385
gas 3.60 15.40 95 413 510
55 4.90 16.00 160 540 425
gas 3.60 33.00 94 610 415
gas 7.60 19.00 160 410 625
<–14 2.00 8.80 75 340 416
–16 2.10 77 478
61 2.00 98 440
–32 2.40 11.10 78 365 520
<–20 2.80 10.70 92 350 590
gas 4.60 84.30 220 3,117 607
60 1.10 55 585
13
Flammable Gases Data (continued)
Cresols (mixed isomers) 1319-77-3 CH3C5H4OH 108.14 191 3.73
Crotonaldehyde 123-73-9 CH3CH=CHCHO 70.09 102 2.41
Cumene 98-82-8 C6H5CH(CH3)2 120.19 152 4.13
Cyclobutane 287-23-0 CH2(CH2)2CH2 56.1 13 1.93
Cycloheptane 291-64-5 CH2(CH2)5CH2 98.19 118.5 3.39
Cyclohexane 110-82-7 CH2(CH2)4CH2 84.2 81 2.90
Cyclohexanol 108-93-0 CH2(CH2)4CHOH 100.16 161 3.45
Cyclohexanone 108-94-1 CH2(CH2)4CO 98.1 156 3.38
Cyclohexene 110-83-8 CH2(CH2)3CH=CH 82.14 83 2.83
Cyclohexylamine 108-91-8 CH2(CH2)4CHNH2 99.17 134 3.42
Cyclopentane 287-92-3 CH2(CH2)3CH2 70.13 50 2.40
Cyclopentene 142-29-0 CH=CHCH2CH2CH 68.12 44 2.30
Cyclopropane 75-19-4 CH2CH2CH2 42.1 -33 1.45
Cyclopropyl methyl ketone 765-43-5 CH3COCHCH2CH2 84.12 114 2.90
p-Cymene 99-87-6 CH3CH6H4CH(CH3)2 134.22 176 4.62
Decahydro-naphthalene trans 493-02-7 CH2(CH2)3CHCH(CH2)3CH2 138.25 185 4.76
Decane (mixed isomers) 124-18-5 C10H22 142.28 173 4.90
Dibutyl ether 142-96-1 (CH3(CH2)3)2O 130.2 141 4.48
Dichlorobenzenes (isomer not stated) 106-46-7 C6H4Cl2 147 179 5.07
Dichlorodiethyl-silane 1719-53-5 (C2H5)SiCl2 157.11 128
1,1-Dichloroethane 75-34-3 CH3CHCl2 99 57 3.42
1,2-Dichloroethane 107-06-2 CH2ClCH2Cl 99 84 3.42
Dichloroethylene 540-59-0 ClCH=CHCl 96.94 37 3.55
1,2-Dichloro-propane 78-87-5 CH3CHClCH2Cl 113 96 3.90
Dicyclopentadiene 77-73-6 C10H12 132.2 170 4.55
Diethylamine 109-89-7 (C2H5)2NH 73.14 55 2.53
Diethylcarbonate 105-58-8 (CH3CH2O)2CO 118.13 126 4.07
Diethyl ether 60-29-7 (CH3CH5)2O 74.1 34 2.55
1,1-Difluoro-ethylene 75-38-7 CH2=CF2 64.03 -83 2.21
Diisobutylamine 110-96-3 ((CH3)2CHCH2)2NH 129.24 137 4.45
Diisobutyl carbinol 108-82-7 ((CH3)2CHCH2)2CHOH 144.25 178 4.97
Diisopentyl ether 544-01-4 (CH3)2CH(CH2)2O(CH2)2CH(CH3)2 158.28 170 5.45
Diisopropylamine 108-18-9 ((CH3)2CH)2NH 101.19 84 3.48
Diisopropyl ether 108-20-3 ((CH3)2CH)2O 102.17 69 3.52
Dimethylamine 124-40-3 (CH3)2NH 45.08 7 1.55
Dimethoxymethane 109-87-5 CH2(OCH)3)2 76.09 41 2.60
3-(Dimethylamino)propiononitrile 1738-25-6 (CH3)2NHCH2CH2CN 98.15 171 3.38
Dimethyl ether 115-10-6 (CH3)2O 46.1 -25 1.59
N,N-Dimethylformamide 68-12-2 HCON(CH3)2 73.1 152 2.51
3,4-Dimethyl hexane 583-48-2 CH3CH2CH(CH3)CH(CH3)CH2CH3 114.23 119 3.87
N,N-Dimethyl hydrazine 57-14-7 (CH3)2NNH2 60.1 62 2.07
1,4-Dioxane 123-91-1 OCH2CH2OCH2CH2 88.1 101 3.03
1,3-Dioxolane 646-06-0 OCH2CH2OCH2 74.08 74 2.55
Dipropylamine 142-84-7 (CH3CH2CH2)2NH 101.19 105 3.48
Ethane 74-84-0 CH3CH3 30.1 -87 1.04
Ethanethiol 75-08-1 CH3CH2SH 62.1 35 2.11
Ethanol 64-17-5 CH3CH2OH 46.1 78 1.59
2-Ethoxyethanol 110-80-5 CH3CH2OCH2CH2OH 90.12 135 3.10
2-Ethoxyethyl acetate 111-15-9 CH3COOCH2CH2OCH2CH3 132.16 156 4.72
Ethyl acetate 141-78-6 CH3COOCH2CH3 88.1 77 3.04
Ethyl acetoacetate 141-97-9 CH3COCH2COOCH2CH3 130.14 181 4.50
Ethyl acrylate 140-88-5 CH2=CHCOOCH2CH3 100.1 100 3.45
Ethylamine 75-04-7 C2H5NH2 45.08 16.6 1.50
Ethylbenzene 100-41-4 CH2CH3C6H5 106.2 135 3.66
Ethyl butyrate 105-54-4 CH3CH2CH2COOC2H5 116.16 120 4.00
Ethylcyclobutane 4806-61-5 CH3CH2CHCH2CH2CH2 84.16 2.90
Ethylcyclohexane 1678-91-7 CH3CH2CH(CH2)4CH2 112.2 131 3.87
Ethylcyclopentane 1640-89-7 CH3CH2CH(CH2)3CH2 98.2 103 3.40
Ethylene 74-85-1 CH2=CH2 28.1 -104 0.97
Flammable Limits
81 1.10 50 555
13 2.10 16.00 82 470 280
31 0.80 6.50 40 328 424
gas 1.80 42
<10 1.10 6.70 44 275
–18 1.00 8.00 35 290 259
61 1.20 11.10 50 460 300
43 1.30 8.40 53 386 419
–17 1.10 8.30 37 244
32 1.10 9.40 47 372 293
–37 1.40 41 320
<–22 1.48 41 309
gas 2.40 10.40 42 183 498
15 1.70 58 452
47 0.70 5.60 39 366 436
54 0.70 4.90 40 284 288
46 0.70 5.60 41 332 201
25 0.90 8.50 48 460 198
86 2.20 9.20 134 564 648
24 3.40 223
–10 5.60 16.00 230 660 440
13 6.20 16.00 255 654 438
–10 9.70 12.80 391 516 440
15 3.40 14.50 160 682 557
36 0.80 43 455
–23 1.70 10.00 50 306 312
24 1.40 11.70 69 570 450
–45 1.70 36.00 60 1,118 160
gas 3.90 25.10 102 665 380
26 0.80 3.60 42 190 256
75 0.70 6.10 42 370 290
44 1.27 104 185
–20 1.20 8.50 49 358 285
–28 1.00 21.00 45 900 405
gas 2.80 14.40 53 272 400
–21 2.20 19.90 71 630 247
50 1.57 62 317
gas 2.70 32.00 51 610 240
58 1.80 16.00 55 500 440
2 0.80 6.50 38 310 305
–18 2.40 20 60 490 240
11 1.40 22.50 51 813 379
–5 2.30 30.50 70 935 245
4 1.20 9.10 50 376 280
gas 2.50 15.50 31 194 515
<–20 2.80 18.00 73 466 295
12 3.10 19.00 59 359 363
40 1.70 15.70 68 593 235
47 1.20 12.70 65 642 380
–4 2.00 2.80 73 470 460
65 1.00 9.50 54 519 350
9 1.40 14.00 59 588 350
<–20 3.50 14.00 49 260 425
23 0.80 7.80 44 340 431
21 1.40 66 435
<–16 1.20 7.70 42 272 212
<24 0.80 6.60 42 310 238
<5 1.05 6.80 42 280 262
2.30 36.00 26 423 425
15
Ethylenediamine 107-15-3 NH2CH2CH2NH2 60.1 118 2.07
Ethylene oxide 75-21-8 CH2CH2O 44 11 1.52
Ethyl formate 109-94-4 HCOOCH2CH3 74.08 52 2.65
Ethyl isobutyrate 97-62-1 (CH3)2CHCOOC2H5 116.16 112 4.00
Ethyl methacrylate 97-63-2 CH2=CCH3COOCH2CH3 114.14 118 3.90
Ethyl methyl ether 540-67-0 CH3OCH2CH3 60.1 8 2.10
Ethyl nitrite 109-95-5 CH3CH2ONO 75.07 2.60
Formaldehyde 50-00-0 HCHO 30 -19 1.03
Formic acid 64-18-6 HCOOH 46.03 101 1.60
2-Furaldehyde 98-01-1 OCH=CHCH=CHCHO 96.08 162 3.30
Furan 110-00-9 CH=CHCH=CHO 68.07 32 2.30
Furfuryl alcohol 98-00-0 OC(CH2OH)CHCHCH 98.1 170 3.38
1,2,3-Trimethyl-benzene 526-73-8 CHCHCHC(CH3)C(CH3)C(CH3) 120.19 175 4.15
Heptane (mixed isomers) 142-82-5 C7H16 100.2 98 3.46
Hexane (mixed isomers) 110-54-3 CH3(CH2)4CH3 86.2 69 2.97
1-Hexanol 111-27-3 C6H13OH 102.17 156 3.50
Hexan-2-one 591-78-6 CH3CO(CH2)3CH3 100.16 127 3.46
Hydrogen 1333-74-0 H2 2 -253 0.07
Hydrogen cyanide 74-90-8 HCN 27 26 0.90
Hydrogen sulphide 7783-06-4 H2S 34.1 -60 1.19
4-Hydroxy-4-methyl-penta-2-one 123-42-2 CH3COCH2C(CH3)2OH 116.16 166 4.00
Kerosene 8008-20-6 150
1,3,5-Trimethylbenzene 108-67-8 CHC(CH3)CHC(CH3)CHC(CH3) 120.19 163 4.15
Methacryloyl chloride 920-46-7 CH2CCH3COCl 104.53 95 3.60
Methane (firedamp) 74-82-8 CH4 16 -161 0.55
Methanol 67-56-1 CH3OH 32 65 1.11
Methanethiol 74-93-1 CH3SH 48.11 6 1.60
2-Methoxyethanol 109-86-4 CH3OCH2CH2OH 76.1 124 2.63
Methyl acetate 79-20-9 CH3COOCH3 74.1 57 2.56
Methyl acetoacetate 105-45-3 CH3COOCH2COCH3 116.12 169 4.00
Methyl acrylate 96-33-3 CH2=CHCOOCH3 86.1 80 3.00
Methylamine 74-89-5 CH3NH2 31.1 -6 1.00
2-Methylbutane 78-78-4 (CH3)2CHCH2CH3 72.15 30 2.50
2-Methylbutan-2-ol 75-85-4 CH3CH2C(OH)(CH3)2 88.15 102 3.03
3-Methylbutan-1-ol 123-51-3 (CH3)2CH(CH2)2OH 88.15 130 3.03
2-Methylbut-2-ene 513-35-9 (CH3)2C=CHCH3 70.13 35 2.40
Methyl chloro-formate 79-22-1 CH3OOCC 94.5 70 3.30
Methylcyclohexane 108-87-2 CH3CH(CH2)4CH2 98.2 101 3.38
Methylcyclo-pentadienes (isomer not stated) 26519-91-5 C6H6 80.13 2.76
Methylcyclopentane 96-37-7 CH3CH(CH2)3CH2 84.16 72 2.90
Methylenecyclo-butane 1120-56-5 C(=CH2)CH2CH2CH2 68.12 2.35
2-Methyl-1-buten-3-yne 78-80-8 HC=CC(CH3)CH2 66.1 32 2.28
Methyl formate 107-31-3 HCOOCH3 60.05 32 2.07
2-Methylfuran 534-22-5 OC(CH3)CHCHCH 82.1 63 2.83
Methylisocyanate 624-83-9 CH3NCO 57.05 37 1.98
Methyl methacrylate 80-62-6 CH3=CCH3COOCH3 100.12 100 3.45
4-Methylpentan-2-ol 108-11-2 (CH3)2CHCH2CHOHCH3 102.17 132 3.50
4-Methylpentan-2-one 108-10-1 (CH3)2CHCH2COCH3 100.16 117 3.45
2-Methylpent-2-enal 623-36-9 CH3CH2CHC(CH3)COH 98.14 137 3.78
4-Methylpent-3-en-2-one 141-79-7 (CH3)2(CCHCOCH)3 98.14 129 3.78
2-Methyl-1-propanol 78-83-1 (CH3)2CHCH2OH 74.12 108 2.55
2-Methylprop-1-ene 115-11-7 (CH3)2C=CH2 56.11 -6.9 1.93
2-Methylpyridine 109-06-8 NCH(CH3)CHCHCHCH 93.13 128 3.21
3-Methylpyridine 108-99-6 NCHCH(CH3)CHCHCH 93.13 144 3.21
4-Methylpyridine 108-89-4 NCHCHCH(CH3)CHCH 93.13 145 3.21
-Methyl styrene 98-83-9 C6H5C(CH3)=CH2 118.18 165 4.08
Methyl tert-pentyl ether 994-05-8 (CH3)2C(OCH3)CH2CH3 102.17 85 3.50
2-Methylthiophene 554-14-3 SC(CH3)CHCHCH 98.17 113 3.40
Morpholine 110-91-8 OCH2CH2NHCH2CH2 87.12 129 3.00
Flammable Limits
34 2.50 18.00 64 396 403
<–18 2.60 100.00 47 1,848 435
–20 2.70 16.50 87 497 440
10 1.60 75 438
20 1.50 70
gas 2.00 10.10 50 255 190
–35 3.00 50.00 94 1,555 95
60 7.00 73.00 88 920 424
42 18.00 57.00 190 1,049 520
60 2.10 19.30 85 768 316
<–20 2.30 14.30 66 408 390
61 1.80 16.30 70 670 370
51 0.80 7.00 470
–4 0.85 6.70 35 281 215
–21 1.00 8.90 35 319 233
63 1.10 47 293
23 1.20 9.40 50 392 533
gas 4.00 77.00 3.4 63 560
<–20 5.40 46.00 60 520 538
gas 4.00 45.50 57 650 270
58 1.80 6.90 88 336 680
38 0.70 5.00 210
44 0.80 7.30 40 365 499
17 2.50 106 510
<–188 4.40 17.00 29 113 537
11 6.00 36.00 73 665 386
4.10 4.10 21.00 80 420
39 1.80 20.60 76 650 285
–10 3.10 16.00 95 475 502
62 1.30 14.20 62 685 280
–3 1.95 16.30 71 581 415
gas 4.20 20.70 55 270 430
–56 1.30 8.30 38 242 420
16 1.40 10.20 50 374 392
42 1.30 10.50 47 385 339
–53 1.30 6.60 37 189 290
10 7.50 26 293 1,020 475
–4 1.00 6.70 41 275 258
<–18 1.30 7.60 43 249 432
<–10 1.00 8.40 35 296 258
<0 1.25 8.60 35 239 352
–54 1.40 38 272
–20 5.00 23.00 125 580 450
<–16 1.40 9.70 47 325 318
–7 5.30 26.00 123 605 517
10 1.70 12.50 71 520 430
37 1.14 5.50 47 235 334
16 1.20 8.00 50 336 475
30 1.46 58 206
24 1.60 7.20 64 289 306
28 1.40 11.00 43 340 408
gas 1.60 10 37 235 483
27 1.20 45 533
43 1.40 8.10 53 308 537
43 1.10 7.80 42 296 534
40 0.80 11.00 44 330 445
<–14 1.50 62 345
–1 1.30 6.50 52 261 433
31 1.40 15.20 65 550 230
17
Naphtha 35 2.50
Naphthalene 91-20-3 C10H8 128.17 218 4.42
Nitrobenzene 98-95-3 CH3CH2NO2 123.1 211 4.25
Nitroethane 79-24-3 C2H5NO2 75.07 114 2.58
Nitromethane 75-52-5 CH3NO2 61.04 102.2 2.11
1-Nitropropane 108-03-2 CH3CH2CH2NO2 89.09 131 3.10
Nonane 111-84-2 CH3(CH2)7CH2 128.3 151 4.43
Octane 111-65-9 CH3(CH2)3CH3 114.2 126 3.93
1-Octanol 111-87-5 CH3(CH2)6CH2OH 130.23 196 4.50
Penta-1,3-diene 504-60-9 CH2=CH-CH=CH-CH3 68.12 42 2.34
Pentanes (mixed isomers) 109-66-0 C5H12 72.2 36 2.48
Pentane-2,4-dione 123-54-6 CH3COCH2COCH3 100.1 140 3.50
Pentan-1-ol 71-41-0 CH3(CH2)3CH2OH 88.15 136 3.03
Pentan-3-one 96-22-0 (CH3CH2)2CO 86.13 101.5 3.00
Pentyl acetate 628-63-7 CH3COO-(CH2)4-CH3 130.18 147 4.48
Petroleum 2.80
Phenol 108-95-2 C6H5OH 94.11 182 3.24
Propane 74-98-6 CH3CH2CH3 44.1 -42 1.56
Propan-1-ol 71-23-8 CH3CH2CH2OH 60.1 97 2.07
Propan-2-ol 67-63-0 (CH3)2CHOH 60.1 83 2.07
Propene 115-07-1 CH2=CHCH3 42.1 -48
Propionic acid 79-09-4 CH3CH2COOH 74.08 141 2.55
Propionic aldehyde 123-38-6 C2H5CHO 58.08 46 2.00
Propyl acetate 109-60-4 CH3COOCH2CH2CH3 102.13 102 3.60
Isopropyl acetate 108-21-4 CH3COOCH(CH3)2 102.13 85 3.51
Propylamine 107-10-8 CH3(CH2)2NH2 59.11 48 2.04
Isopropylamine 75-31-0 (CH3)2CHNH2 59.11 33 2.03
Isopropyl Chloroacetate 105-48-6 ClCH2COOCH(CH3)2 136.58 149 4.71
2-Isopropyl-5-methylhex-2-enal 35158-25-9 (CH3)2CH-C(CHO)CHCH2CH(CH3)2 154.25 189 5.31
Isopropyl nitrate 1712-64-7 (CH3)2CHONO2 105.09 101
Propyne 74-99-7 CH3C=CH 40.06 -23.2 1.38
Prop-2-yn-1-ol 107-19-7 HC=CCH2OH 56.06 114 1.89
Pyridine 110-86-1 C5H5N 79.1 115 2.73
Styrene 100-42-5 C6H5CH=CH2 104.2 145 3.60
Tetrafluoroethylene 116-14-3 CF2=CF2 100.02 3.40
2,2,3,3-Tetrafluoropropyl acrylate 7383-71-3 CH2=CHCOOCH2CF2CF2H 186.1 132 6.41
2,2,3,3-Tetrafluoropropyl methacrylate 45102-52-1 CH2=C(CH2)COOCH2CF2CF2H 200.13 124 6.90
Tetrahydrofuran 109-99-9 CH2(CH2)2CH2O 72.1 64 2.49
Tetrahydrofurfuryl alcohol 97-99-4 OCH2CH2CH2CHCH2OH 102.13 178 3.52
Tetrahydrothiophene 110-01-0 CH2(CH2)2CH2S 88.17 119 3.04
N,N,N’, N’-Tetramethyldiaminomethane 51-80-9 (CH3)2NCH2N(CH3)2 102.18 85 3.50
Thiophene 110-02-1 CH=CHCH=CHS 84.14 84 2.90
Toluene 108-88-3 C6H5CH3 92.1 111 3.20
Triethylamine 121-44-8 (CH3CH2)3N 101.2 89 3.50
1,1,1-Trifluoroethane 420-46-2 CF3CH3 84.04 2.90
2,2,2-Trifluoroethanol 75-89-8 CF3CH2OH 100.04 77 3.45
Trifluoroethylene 359-11-5 CF2=CFH 82.02 2.83
3,3,3-Trifluoro-prop-1-ene 677-21-4 CF3CH=CH2 96.05 -16 3.31
Trimethylamine 75-50-3 (CH3)3N 59.1 3 2.04
2,2,4-Trimethylpentane 540-84-1 (CH3)2CHCH2C(CH3)3 114.23 98 3.90
2,4,6-Trimethyl-1,3,5-trioxane 123-63-7 OCH(CH3)OCH(CH3)OCH(CH3) 132.16 123 4.56
1,3,5-Trioxane 110-88-3 OCH2OCH2OCH2 90.1 115 3.11
Turpentine C10H16 149
Isovaleraldehyde 590-86-3 (CH3)2CHCH2CHO 86.13 90 2.97
Vinyl acetate 108-05-4 CH3COOCH=CH2 86.09 72 3.00
Vinylcyclohexenes (isomer not stated) 100-40-3 CH2CHC6H9 108.18 126 3.72
Vinylidene chloride 75-35-4 CH2=CCl2 96.94 30 3.40
2-Vinylpyridine 100-69-6 NC(CH2=CH)CHCHCHCH 105.14 79 3.62
4-Vinylpyridine 100-43-6 NCHCHC(CH2=CH)CHCH 105.14 62 3.62
Xylenes 1330-20-7 C6H4(CH3)2 106.2 144 3.66
Flammable Limits
<–18 0.90 6.00 290
77 0.60 5.90 29 317 528
88 1.40 40.00 72 2,067 480
27 3.40 107 410
36 7.30 63.00 187 1,613 415
36 2.20 82 420
30 0.70 5.60 37 301 205
13 0.80 6.50 38 311 206
81 0.90 7.00 49 385 270
<–31 1.20 9.40 35 261 361
–40 1.40 7.80 42 261 258
34 1.70 71 340
38 1.06 10.50 36 385 298
12 1.60 58 445
25 1.00 7.10 55 387 360
<–20 1.20 8.00 560
75 1.30 9.50 50 370 595
gas 1.70 10.90 31 200 470
22 2.10 17.50 52 353 405
12 2.00 12.70 50 320 425
gas 2.00 11.10 35 194 455
52 2.10 12.00 64 370 435
<–26 2.00 47 188
10 1.70 8.00 70 343 430
4 1.70 8.10 75 340 467
–37 2.00 10.40 49 258 318
<–24 2.30 8.60 55 208 340
42 1.60 89 426
41 3.05 192 188
11 2.00 100.00 75 3,738 175
gas 1.70 16.8 28 280 340
33 2.40 55 346
17 1.70 12.40 56 398 550
30 1.00 8.00 42 350 490
gas 10.00 59.00 420 2,245 255
45 2.40 182 357
46 1.90 155 389
–20 1.50 12.40 46 370 224
70 1.50 9.70 64 416 280
13 1.00 12.30 42 450 200
<–13 1.61 67 180
–9 1.50 12.50 50 420 395
4 1.10 7.80 39 300 535
–7 1.20 8.00 51 339
6.80 17.60 234 605 714
30 8.40 28.80 350 1,195 463
27.00 502 904 319
4.70 184 490
gas 2.00 12.00 50 297 190
–12 0.70 6.00 34 284 411
27 1.30 72 235
45 3.20 29.00 121 1,096 410
35 0.80 254
–12 1.30 13.00 60 207
–8 2.60 13.40 93 478 425
15 0.80 35 257
–18 6.50 16.00 260 645 440
35 1.20 51 482
43 1.10 47 501
30 1.00 7.60 44 335 464
19
6 Toxic Gas 1 MILLION
Hazards
BALLS
Some gases are poisonous and can be dangerous to life at very low
concentrations. Some toxic gases have strong smells like the distinctive
‘rotten eggs’ smell of Hydrogen Sulphide (H2S). The measurements most
often used for the concentration of toxic gases are parts per million (ppm) m)
and parts per billion (ppb). For example 1ppm would be equivalent to a
room filled with a total of 1 million balls and 1 of those balls being red.
The red ball would represent 1ppm.
M
ore people die from toxic gas treating flammable and toxic gases separately can interact and
d produce
exposure than from explosions is that the hazards and regulations involved ect when
a far worse effect
caused by the ignition of and the types of sensor required are different. combined than the separate
flammable gas. (It should be effect of each on its own.
noted that there is a large group of gases With toxic substances, apart from the obvious
which are both combustible and toxic, so environmental problems, the main concern Concern about concentrations of toxic
that even detectors of toxic gases is the effect on workers of he workplace focus on both
substances in the
sometimes have to carry hazardous exposure to even very low rganic compounds,
organic and inorganic compounds including
area approval). The main reason for concentrations, which could be the effects they could have on the health
inhaled, ingested, or absorbed and safety of employees, the possible
through the skin. Since adverse contamination of a manufactured end-product
effects can often result from (or equipment used in its manufacture) and
additive, long-term exposure, also the subsequent disruption of normal
it is important not only to working activities.
measure the concentration of
gas, but also the total time of
exposure. There are even some
known cases of synergism,
where substances
Workplace
Exposure
Limits
The term ‘workplace exposure limits’ or ‘occupational
hazard monitoring’
m is generally used to cover the area of
industrial health monitoring associated with the exposure
industria
employees to hazardous conditions of gases, dust,
of emplo
etc. In other words, the aim is to ensure that levels
noise etc
workplace are below the statutory limits.
in the wo
T
his subjec
subject covers both area Whatever method is decided upon, it is
1 RED surveys (p
(profiling of potential important to take into account the nature of
BALL exposures) and personal
exposures the toxicity of any of the gases involved.
monitoring, where instruments are
monitoring For instance, any instrument which
worn by a worker and sampling is carried out measures only a time-weighted average,
as near to the breath
breathing zone as possible. or an instrument which draws a sample for
100%V/V = 1,000,000ppm This ensures that the measured level of subsequent laboratory analysis, would not
1%V/V = 10,000ppm contamination is trul
truly representative of that protect a worker against a short exposure to
EXAMPLE inhaled by the worke
worker. a lethal dose of a highly toxic substance. On
100%LEL Ammonia = 15%V/V the other hand, it may be quite normal to briefly
50%LEL Ammonia = 7.5%V/V It should be emphas
emphasised that both personal exceed the average, Long-Term Exposure Limit
50%LEL Ammonia = 75,000ppm monitoring and monitoring
moni of the workplace (LTEL) levels in some areas of a plant, and it
should be considered as important parts of an need not be indicated as an alarm situation.
overall, integrated sa
safety plan. They are only Therefore, the optimum instrument system
intended to provide the necessary information should be capable of monitoring both short
about conditions as they exist in the and long-term exposure levels as well as
atmosphere. This then allows the necessary instantaneous alarm levels.
action to be taken to comply with
therelevantindustrialregulations
and safety requirements.
21
Toxic Exposure Limits
European Occupational GAS
Exposure Limits FACT
Hydrogen is the
Occupational Exposure Limit values (OELs) are set by competent lightest, most
abundant and
national authorities or other relevant national institutions as limits for explosive gas on
concentrations of hazardous compounds in workplace air. OELs for Earth.
hazardous substances represent an important tool for risk assessment
and management and valuable information for occupational safety and
health activities concerning hazardous substances.
O
ccupational Exposure Limits can concentration varies from substance to for a shorter time. The potency to penetrate
apply both to marketed products substance according to its toxicity. The through skin is annotated in the WEL list by
and to waste and by-products exposure times are averaged for eight hours remark “Skin”. Carcinogenicity, reproduction
from production processes. (8-hour Time-Weighted Average TWA) and toxicity, irritation and sensitisation potential
The limits protect workers against health 15 minutes (Short-Term Exposure Limit STEL). are considered when preparing a proposal
effects, but do not address safety issues For some substances, a brief exposure is for an OEL according to the present
such as explosive risk. As limits frequently considered so critical that they are set only scientific knowledge.
change and can vary by country, you should a STEL, which should not be exceeded even
consult your relevant national authorities to
ensure that you have the latest information.
Occupational Exposure Limits in the UK

function under the Control of Substances
Hazardous to Health Regulations (COSHH).
The COSHH regulations require the employer
to ensure that the employee’s exposure to
substances hazardous to health is either
prevented or if not practically possible,
adequately controlled.
As of 6 April 2005, the regulations introduced

a new, simpler Occupational Exposure Limit
system. The existing requirements to follow
good practice were brought together by
the introduction of eight principles in the
Control of Substances Hazardous to Health
(Amendment) Regulations 2004.
Maximum Exposure Limits (MELs) and

Occupational Exposure Standards (OESs)
were replaced with a single type of limit -
the Workplace Exposure Limit (WEL). All
the MELs, and most of the OESs, are being
transferred into the new system as WELs and
will retain their previous numerical values.
The OESs for approximately 100 substances
were deleted as the substances are now
banned, scarcely used or there is evidence
to suggest adverse health effects close to
the old limit value. The list of exposure limits
is known as EH40 and is available from the
UK Health and Safety Executive. All legally
enforceable WELs in the UK are air limit
values. The maximum admissible or accepted
Effects of exposure
p to Carbon Monoxide
Carbon Monoxide in parts per million (ppm)
2500
2000
1500
1000
= Noticeable symtoms
/ start to feel unwell
500 = Feeling ill
= Death
5 10 20 40 80 160
Period of exposure in minutes
23
US Occupational
Exposure Limits
T
he Occupational Safety systems The ACGIH defines different TLV-Types as:
in the United States vary from
state to state. Here, information is Threshold Limit Value – Time-Weighted
given on 3 major providers of the Average (TLV-TWA): the Time-Weighted
Occupational Exposure Limits in the USA - Average concentration for a conventional
ACGIH, OSHA, and NIOSH. 8-hour workday and a 40-hour workweek,
to which it is believed that nearly all workers
The American Conference of Governmental may be repeatedly exposed, day after day,
Industrial Hygienists (ACGIH) publishes without adverse effect.
Maximum Allowable Concentrations (MAC),
which were later renamed to “Threshold Limit Threshold Limit Value – Short-Term
Values” (TLVs). Exposure Limit (TLV-STEL): the
concentration to which it is believed that
Threshold Limit Values are defined as an workers can be exposed continuously for
exposure limit “to which it is believed nearly a short period of time without suffering
all workers can be exposed day after day from irritation, chronic or irreversible tissue
for a working lifetime without ill effect”. The damage, or narcosis. STEL is defined as a
ACGIH is a professional organisation of 15-minute TWA exposure, which should not
occupational hygienists from universities be exceeded at any time during a workday.
or governmental institutions. Occupational
hygienists from private industry can join as Threshold Limit Value – Ceiling (TLV-C):
associate members. Once a year, the different the concentration that should not be
committees propose new threshold limits exceeded during any part of the working
or best working practice guides. The list exposure.
of TLVs includes more than 700 chemical
substances and physical agents, as well as There is a general excursion limit
dozens of Biological Exposure Indices for recommendation that applies to those
selected chemicals. TLV-TWAs that do not have STELs.
Excursions in worker exposure levels may
Occupational Exposure Limits Comparison Table

ACGIM OSHA NIOSH EH40 Meaning
Threshold Limit Permissible Exposure Recommended Workplace Exposure Limit definition
Values (TLVs) Limits (PELs) Exposure Levels (RELs) Limits (WELs)
TLV-TWA TWA TWA TWA Long-term Exposure Limit
(8hr-TWA reference period)
TLV-STEL STEL STEL STEL Short-Term Exposure Limit
(15-minute exposure period)
TLV-C Ceiling Ceiling - The concentration that should
not be exceeded during any
part of the working exposure
Excursion Limit Excursion Limit - - Limit if no STEL stated
- BEIs BEIs - Biological Exposure Indicies
exceed 3 times the TLV-TWA for no more than in the air and they are enforceable. The initial limits via criteria documents to OSHA and
a total of 30 minutes during a workday and set of limits from 1971 was based on the other OEL setting institutions. Types of
under no circumstances should they exceed 5 ACGIH TLVs. OSHA currently has around RELs are TWA, STEL, Ceiling and BEIs.
times the TLV-TWA, provided that the 500 PELs for various forms of approximately The recommendations and the criteria are
TLV-TWA is not exceeded. 300 chemical substances, many of which are published in several different document types,
widely used in industrial settings. Existing suchasCurrentIntelligentBulletins(CIB),Alerts,
ACGIH-TLVs do not have a legal force in the PELs are contained in a document called Special Hazard Reviews, Occupational Hazard
USA, they are only recommendations. OSHA “29 CFR 1910.1000”, the air contaminants Assessments and Technical Guidelines.
defines regulatory limits. However, standard. OSHA uses in a similar way as
ACGIH-TLVs and the criteria documents are a the ACGIH the following types of OELs:
very common base for setting TLVs in the USA TWAs, Action Levels, Ceiling Limits, STELs,
and in many other countries. ACGIH exposure Excursion Limits and in some cases Biological
limits are in many cases more protective than Exposure Indices (BEIs).
OSHA’s. Many US companies use the current
ACGIH levels or other internal and more The National Institute for Occupational
protective limits. Safety and Health (NIOSH) has the statutory
responsibility for recommending exposure
The Occupational Safety and Health levels that are protective to workers.
Administration (OSHA) of the US Department NIOSH has identified Recommended
of Labor publishes Permissible Exposure Exposure Levels (RELs) for around 700
Limits (PEL). PELs are regulatory limits on hazardous substances. These limits have
the amount or concentration of a substance no legal force. NIOSH recommends their
25
Toxic Gases Data The toxic gases listed below can be detected using equipment supplied by Honeywell Gas Detection. Gas data is supplied where known.
As product development is ongoing, contact Honeywell Analytics if the gas you require is not listed.
Data may change by country and date, always refer to local up-to-date regulations.
Common Name CAS Number Formula

Ammonia 7664-41-7 NH3
Arsine 7784-42-1 AsH3
Boron Trichloride 10294-34-5 BCl3
Boron Trifluoride 7637-07-2 BF3
Bromine 7726-95-6 Br2
Carbon Monoxide 630-08-0 CO
Chlorine 7782-50-5 Cl2
Chlorine Dioxide 10049-04-4 ClO2
1,4 Cyclohexane diisocyanate CHDI
Diborane 19287-45-7 B2H6
Dichlorosilane (DCS) 4109-96-0 H2Cl2Si
Dimethyl Amine (DMA) 124-40-3 C2H7N
Dimethyl Hydrazine (UDMH) 57-14-7 C2H8N2
Disilane 1590-87-0 Si2H6
Ethylene Oxide 75-21-8 C2H4O
Fluorine 7782-41-4 F2
Germane 7782-65-2 GeH4
Hexamethylene Diisocyanate (HDI) 822-06-0 C8H12N2O2
Hydrazine 302-01-2 N2H4
Hydrogen 1333-74-0 H2
Hydrogen Bromide 10035-10-6 HBr
Hydrogen Chloride 7647-01-0 HCl
Hydrogen Cyanide 74-90-8 HCN
Hydrogen Fluoride 7664-39-3 HF
Hydrogen Iodide 10034-85-2 HI
Hydrogen Peroxide 7722-84-1 H2O2
Hydrogen Selenide 7783-07-5 H2Se
Hydrogen Sulphide 7783-06-4 H2S
Hydrogenated Methylene Bisphenyl Isocyanate (HMDI)
Isocyanatoethyl Methacrylate (IEM) C7H9NO3
Isophorone Diisocyanate (IPDI) C12H18N2O2
Methyl Fluoride (R41) 593-53-3 CH3F
Methylene Bisphenyl Isocyanate (MDI) 101-68-8 C15H10N2O2
Methylene Bisphenyl Isocyanate -2 (MDI-2) 101-68-8 C15H10N2O2
Methylenedianiline (MDA) 101-77-9 C13H14N2
Monomethyl Hydrazine (MMH) 60-34-4 CH6N2
Naphthalene Diisocyanate (NDI) 3173-72-6 C12H6N2O2
Nitric Acid 7697-37-2 HNO3
Ref: EH40/2005 Workplace Exposure Limits, OSHA Standard 29 CFR 1910.1000 tables Z-1 and Z-2 and ACGIH Threshold Limit Valves and
Biological Exposure Indices Book 2005.
EH40 Workplace Exposure Limit (WEL) OSHA Permissible

Exposure Limits (PEL)
Long-Term Exposure Limit Short-Term Exposure Limit Long-term Exposure Limit
(8-hour TWA reference period) (15-minute reference period) (8-hour TWA reference period)
ppm mg/m3 ppm mg/m3 ppm mg/m3

25 18 35 25 50 35
0.05 0.16 0.05 0.2
1 (ceiling) 3 (ceiling)
0.1 0.66 0.2 1.3 0.1 0.7
30 35 200 232 50 55
0.5 1.5 1 (ceiling) 3 (ceiling)
0.1 0.28 0.3 0.84 0.1 0.3
0.1 0.1
2 3.8 6 11 10 18
5 9.2 1.5
1 1.6 1 1.6 0.1 0.2
0.2 0.64 0.6 1.9
0.02 0.03 0.1 0.13 1 1.3
3 10 3 10
1 2 5 8 5 (ceiling) 7 (ceiling)
10 11 10 11
1.8 1.5 3 2.5 2
1 1.4 2 2.8 1 1.4

0.05 0.2
5 7 10 14 2 10
0.01 0.08
1 2.6 2 5
27
Toxic Gases Data (continued)
Common Name CAS Number Formula

Nitric Oxide 10102-43-9 NO
Nitrogen Dioxide 10102-44-0 NO2
Nitrogen Trifluoride 7783-54-2 NF3
n-Butyl Amine (N-BA) 109-73-9 C4H11N
Ozone 10028-15-6 O3
Phosgene 75-44-5 COCl2
Phosphine 7803-51-2 PH3
Propylene Oxide 75-56-9 C3H6O
p-Phenylene Diamine (PPD) 106-50-3 C6H8N2
p-Phenylene Diisocyanate (PPDI) 104-49-4 C8H4N2O2
Silane 7803-62-5 SiH4
Stibine 7803-52-3 SbH3
Sulphur Dioxide 7446-09-5 SO2
Sulphuric Acid 7664-93-9 H2SO4
Tertiary Butyl Arsine (TBA)
Tertiary Butyl Phosphine (TBP) 2501-94-2 C4H11P
Tetraethyl Orthosilicate (TEOS) 78-10-4 C8H20O4Si
Tetrakis (Dimethylamino) Titanium (TDMAT) 3275-24-9 C8H24N4Ti
Tetramethyl Xylene Diisocyanate (TMXDI) C14H16N2O2
Toluene Diamine (TDA) 95-80-7 C7H10N2
Toluene Diisocyanate (TDI) 584-84-9 C9H6N2O2
Triethyl Amine (TEA) 121-44-8 C6H15N
Trimethylhexamethylene Diisocyanate (TMDI) C11H18N2O2
Unsymmetrical Dimethylhydrazine (UDMH) 57-14-7 C2H8N2
EH40 Workplace Exposure Limit (WEL) OSHA Permissible
Exposure Limits (PEL)
Long-Term Exposure Limit Short-Term Exposure Limit Long-term Exposure Limit
(8-hour TWA reference period) (15-minute reference period) (8-hour TWA reference period)
ppm mg/m3 ppm mg/m3 ppm mg/m3

25 30
10 29
0.2 0.4 0.1 0.2
0.02 0.08 0.06 0.25 0.1 0.4
0.1 0.14 0.2 0.28 0.3 0.4
5 12 100 240
0.1 0.1
0.5 0.67 1 1.3

0.1 0.5
5 13
1
50 191 150 574

0.02 (ceiling) 0.14 (ceiling)
2 8 4 17 2.5 100
29
7 Asphyxiant
Hazard
OXYGEN DEPLETION
CAN BE CAUSED BY:
• Displacement
(Oxygen Deficiency) • Combustion

• Oxidation
• Chemical reaction
• Bacterial action
We all need to breathe the Oxygen (O2) in air to live.
Air is made up of several different gases including
Oxygen. Normal ambient air contains an Oxygen
20.9%
concentration of 20.9% v/v. When the Oxygen level
falls below 19.5% v/v, the air is considered
Oxygen-deficient. Oxygen concentrations below
16% v/v are considered unsafe for humans.
v/v normal
100%
v/v O2
16%
v/v depletion
0% 6%
v/v O2 v/v fatal
8 Oxygen GAS
Enrichment FACT
The atomic weight of
Radon is 222 atomic mass
units making it the heaviest
known gas. It is 220 times
heavier than the lightest
gas, Hydrogen.
It is often forgotten that Oxygen enrichment can also

cause a risk. At increased O2 levels the flammability
of materials and gases increases. At levels of 24%
items such as clothing can spontaneously combust.
Oxyacetylene welding equipment combines

Oxygen and Acetylene gas to produce an extremely
high temperature. Other areas where hazards may
arise from Oxygen enriched atmospheres include
manufacturing areas for storing rocket propulsion
systems, products used for bleaching in the pulp and
paper industry and clean water treatment facilities.
Sensors have to be specially certified for use in

O2 enriched atmospheres.
31
9 Typical Areas
that Require
Gas Detection
There are many different applications for fixed and portable gas detection. Industrial
processes increasingly involve the use and manufacture of highly dangerous substances,
particularly toxic and combustible gases. Inevitably, occasional escapes of gas occur,
which create a potential hazard to the plant, its employees and people living nearby.
Worldwide incidents involving asphyxiation, explosions and loss of life, are a constant
reminder of this problem.
Oil and gas (drilling Refineries and Chemical plants Power generation
and production) petrochemical Chemical plants manufacture (traditional and
The oil and gas industry covers facilities a myriad of products and renewable)
a large number of upstream feedstocks. The nature and Traditionally fossil fuels like coal,
Refineries take crude oil mixes
activities from the on and diversity of chemicals used oil and Natural Gas have been
and convert them into various
offshore exploration and and produced on site provide used to generate electricity.
blends of Hydrocarbons for use
production of oil and gas to its considerable danger to assets Today renewable energy is
in a wide variety of subsequent
transportation and storage. and personnel. These plants becoming a key aspect of power
products.
The Hydrocarbon gases involved often use a wide range of both generation with wind power and
are a serious explosive risk Typical Applications: flammable and toxic gases in biogas becoming more prevalent
and toxic gases such as • Flanges and pump seals for their manufacturing processes. forms of power generation.
Hydrogen Sulphide are often Hydrocarbon detection
Typical Applications:
present. • Catalytic cracking process Typical Applications:
• Raw material storage • Around boiler pipework and
monitoring
Typical Applications: • Process areas burners
• Bulk storage areas
• Exploration drilling rigs • Laboratories • In and around turbine
• Water drains, run-off gullies
• Production platforms • Pump rows packages
and trenches
• Onshore oil and gas terminals • Compressor stations • Working near landfill gas
• Confined space entry
• Facilityturnarounds/shutdowns • Loading/unloading areas pipework
• Loading areas
• LPG storage areas • Ventilation systems Typical Gases: • Surface emissions monitoring
• Offshore and onshore drilling • Perimeter/fence-line Flammable: Various in landfills
and service rigs monitoring Hydrocarbons including • Blade production and welding
• Offshore production platforms • Planned maintenance and Petroleum and resins of steel parts (wind energy
• Personal Protective Equipment shutdown/plant modification Toxic: Various including manufacture)
(PPE) Hydrogen Sulphide, • Confined spaces (in the tower
Typical Gases:
Typical Gases: Hydrogen Fluoride and Ammonia and nacelle)
Flammable: Various
Flammable: Various • Working near landfill leachate
Hydrocarbon gases including
Hydrocarbon gases including pools and perimeter boreholes
Ethylene, Kerosene, Propane
Methane
and Methane Typical Gases:
Toxic: Hydrogen Sulphide,
Toxic: Hydrogen Sulphide and Flammable: Natural Gas,
Carbon Monoxide
Sulphur Dioxide Hydrogen
Oxygen: Depletion Oxygen: Depletion Toxic: Carbon Monoxide,
Sulphur Oxide, Nitrogen Oxide,
Hydrogen Sulphide, VOCs
Oxygen: Depletion
We have produced various technical documents
regarding applications for gas detection. If you would
like to access this information, please visit
www.honeywellanalytics.com for fixed gas detection
applications and www.gasmonitors.com for portable
gas detection applications.
Water treatment Marine Military and Pulp and paper

Water treatment is a large industry Marine gas hazards are national security production
comprising of many processes numerous. Liquid gas, fuel, The World’s militaries require This vast industry includes both
and aspects from the production chemicals and other fossil fuels gas detection monitoring and mechanical and chemical pulping
and distribution of clean water harbour a risk of explosion. due to their mobility, portable methods that turn wood into a
to the collection, treatment There is a danger of suffocation gas detection forms a key part variety of paper based products.
and disposal of waste such as from Oxygen displacement when of protection against dangerous Toxic gas threats are present from
sewage. using Nitrogen or other gases gases. bleaching agents, whilst fuels
for inerting. Toxic gases like used to drive mechanical pulping
Typical Applications: Typical Applications:
Hydrogen Sulphide also pose create flammable gas risks.
• Purification plant monitoring • Fuel storage tanks
considerable risks.
• Sewage digesters (including inspection) Typical Applications:
• Plant sumps Typical Applications: • Transportation • Digesters (in chemical pulping)
• Plant intakes and penstocks • Clearance measurements of (particularly of fuel) • Chlorine during bleaching
• Plant power generation tanks and cargo bays • Vehicle refuelling • Fuel monitoring in mechanical
monitoring • Ship hold inspections • Aircraft tank inspections pulping
• Hydrogen Sulphide scrubbers • Vessel entry/below deck entry • Submarine septic tanks and
• Confined spaces, e.g. electric Typical Gases:
Typical Gases: Hydrogen build-up
motor room, hold spaces and Flammable: Methane
Flammable: Various • Naval vessels engine room
inter-barrier spaces Toxic: Chlorine, Chlorine Dioxide
Hydrocarbons including Methane monitoring and septic tanks
• Inerting and purging and Ozone
Toxic: Hydrogen Sulphide, • Equipment and vehicle
• Leak detection Oxygen: Depletion
Carbon Dioxide, Chlorine, maintenance
• Airlocks
Sulphur Dioxide and Ozone Typical Gases:
• Burner platform vent hoods
Oxygen: Depletion Flammable: Various blends of
• Engine room gas supply
pipelines Aviation Kerosene, Diesel and
Gasoline
Typical Gases: Toxic: Carbon Monoxide,
Flammable: Various Carbon Dioxide,
Hydrocarbons including Hydrogen Sulphide and
Liquid Natural Gas and Methane VolatileOrganicCompounds(VOCs)
Toxic: Hydrogen Sulphide and Oxygen: Depletion
Carbon Monoxide
Oxygen: Depletion
33
Typical Areas that Require Gas Detection (continued)
Printing Semiconductor Photovoltaics Confined spaces

Depending on the materials Manufacturing semiconductor With more focus on renewable These locations provide one of the
being printed, processes within materials involves the use of toxic energy, the photovoltaic (PV) key application uses for portable
the printing industry use various and flammable gas. Phosphine, industry is experiencing gas detectors, owing to their ability
solvents, inks and dangerous Arsenic, Boron Trichloride and considerable growth. PV for dangerous gases to build up
chemicals, which are often dried Gallium are commonly used as applications use semiconductors (see Confined spaces on page 60
in very hot ovens, creating the doping agents. Hydrogen is that exhibit the photovoltaic effect for detailed information).
need for robust gas detection to used both as a reactant and a in order to convert solar radiation
ensure process safety. reducing atmosphere carrier into direct current electricity, and
• Shafts
gas. Etching and cleaning gases therefore use a semiconductor
Typical Applications: • Trenches
include Ammonia and other manufacturing process.
• Bulk storage of inks and • Sewers and manholes
perfluoro compounds.
varnishes Typical Applications: • Pits
• Dryers and ovens Typical Applications: • Wafer reactor • Boilers
• Exhaust monitoring • Wafer reactor • Wafer dryers • Tunnels
• Wafer dryers • Gas cabinets • Tanks
Typical Gases:
• Gas cabinets • Chemical Vapour Deposition • Vessels (including marine
Flammable: Various
• Chemical Vapour Deposition vessel tanks)
Hydrocarbons including solvents Typical Gases:
• Pipelines
and Methane Typical Gases: Flammable: Hydrogen, Propane,
• Containers
Flammable: Hydrogen, Propane, Silane and Methane
Silane and Methane Toxic: Hydrogen Chloride, Arsine, Typical Gases:
Toxic: Hydrogen Chloride, Arsine, Boron Trichloride, Phosphine, Flammable: Methane
Boron Trichloride, Phosphine, Carbon Monoxide, Toxic: Carbon Monoxide and
Carbon Monoxide, Hydrogen Fluoride, Hydrogen Sulphide
Hydrogen Fluoride, Ozone, Dichlorosilane, Oxygen: Depletion
Ozone, Dichlorosilane, Tetraethyl Orthosilicate,
Tetraethyl Orthosilicate, Hexafluorobutadiene 1,3,
Hexafluorobutadiene 1,3, Octafluorocyclopentene,
Tunnels and Octafluorocyclopentene, Germane, Ammonia and
car parks Germane, Ammonia and Nitrogen Dioxide
Exhaust fumes can build-up in Nitrogen Dioxide Oxygen: Depletion
car parks and tunnels, creating Oxygen: Depletion
toxic gas hazards. Gas detection
is used to monitor the build up
of gases like Carbon Monoxide
Building and
and Methane and also control the construction
ventilation systems. Various dangerous chemicals
are used during construction
Typical Applications: work and due to the mobility of
• Car tunnels operatives in these applications,
• Underground and portable gas detection forms an
enclosed car parks integral part of on-site Personal
• Ventilation control Protective Equipment (PPE)
• Access tunnels
Typical Gases: Typical Applications:
Flammable: Methane, • Trenching and shoring
Liquid Petroleum Gas and Typical Gases:
Petrol vapour Flammable: Methane
Toxic: Carbon Monoxide and Toxic: Carbon Monoxide and
Nitrogen Dioxide Hydrogen Sulphide
Oxygen: Depletion
34
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Typical Areas that Require Gas Detection (continued)
Ammonia Steel Mills Agriculture and live Commercial

Refrigeration Due to the large number of stock buildings and public
Many industries use refrigeration furnaces and processes that When it comes to keeping facilities
as part of their processes – from subject metals to extreme heat, livestock, Methane and Ammonia Commercial and public facilities
food and beverage manufacture, Carbon Monoxide detection is can build-up to dangerous levels like swimming pools, shopping
gas liquefaction and chemical essential throughout the plant. in cattle sheds. Agricultural stores centres and schools use
manufacture to cryogenics and Typical Applications: where fertilisers and pesticide integrated safety systems, which
Liquid Natural Gas shipping. • Furnace monitoring stocks are held can also pose can include gas detection.
It is essential to ensure that • Oven monitoring additional explosive dangers. Large visitor numbers can increase
Ammonia does not build-up, the risk of Carbon Dioxide
Typical Gases: Typical Applications:
causing potentially explosive build-up and heating systems
Toxic: Carbon Monoxide • Cattle shed monitoring
atmospheres. may also need to be monitored
• Agricultural fertiliser and
Typical Applications: chemical stores for flammable gas leaks.
• Ammonia storage areas Typical Applications:
• Plant room valves, joints • Mechanical rooms
and seals • Swimming pools
• Chiller and refrigerator • Schools
monitoring • Heating pipework monitoring
• Air conditioning systems • Indoor air quality monitoring
Typical Gases: Landfill monitoring and Typical Gases:
Flammable: Ammonia Biogas generation Flammable: Methane
Toxic: Ammonia Landfills are designed to promote
Mining Toxic: Carbon Dioxide,
There is an abundance of mineral Carbon Monoxide, Chlorine
and accelerate the decomposition
and fossil fuel reserves being Oxygen: Depletion
of organic material and may also
mined globally, leaving personnel
contain sorting and storage areas
at risk from dangerous gas
for inorganic material. Landfill gas
build-ups in the enclosed spaces
(known as Biogas), is often collected
of mine shafts. This makes portable
at these sites so care should be
gas detection an essential
taken when personnel are working
component of mining safety.
close to potential sources.
Laboratory and Typical Applications:
medical • When working near leachate
• Excavation
Laboratories and medical pools
• Continuous monitoring whilst Turnarounds, plant
facilities like hospitals may use • When working near perimeter
working in shafts shutdowns and
many different flammable and boreholes Typical Gases: planned equipment
toxic substances. Very large • When working near landfill gas Flammable: Methane modifications
installations may also feature pipework Toxic: Carbon Monoxide No matter what the industry and
their own on-site utility supplies • When monitoring surface Oxygen: Depletion application, planned shutdowns
and back-up power stations. emissions and maintenance schedules
Typical Applications: • When working near create additional risks on site
• Laboratories weighbridges because they represent deviations
• Cryogenics and refrigeration • When handling waste from standard processes.
• Boiler rooms Gas detection in the form of
Typical Gases:
portable monitoring solutions
Typical Gases: Flammable: Methane
should always be used to limit
Flammable: Methane and Toxic: Carbon Dioxide,
these risks when modifying
Hydrogen Hydrogen Sulphide, Benzene
aspects or processes of the plant.
Toxic: Carbon Monoxide, and Toulene
Chlorine, Ammonia and Oxygen: Depletion
Ethylene Oxide
Oxygen: Depletion/enrichment
35
10 Principles of
Detection
Combustible Gas
Sensors
Many people have probably seen a flame safety
lamp at some time and know something about its
use as an early form of ‘firedamp’ (the gases found
in coal mines. Also known as “minedamp”) gas
detector in underground coal mines and sewers.
Although originally intended as a source of light, the
device could also be used to estimate the level of
combustible gases - to an accuracy of about 25-50%,
depending on the user’s experience, training, age,
colour perception etc.
Modern combustible gas detectors have to be much

more accurate, reliable and repeatable than this and
although various attempts were made to overcome
the safety lamp’s subjectiveness of measurement
(by using a flame temperature sensor for instance),
it has now been almost entirely superseded by more
modern, electronic devices.
Catalytic
Nevertheless, today’s most commonly used device,
the catalytic detector, is in some respects a modern
development of the early flame safety lamp, since it
sensor
Nearly all modern, low-cost, combustible
also relies for its operation on the combustion of a gas gas detection sensors are of the
and its conversion to Carbon Dioxide and water. electro-catalytic type. They consist of a very
small sensing element sometimes called
a ‘bead’, a ‘Pellistor’, or a ‘Siegistor’- the
last two being registered trade names for
Controller Detector
commercial devices. They are made of an
electrically heated Platinum wire coil, covered
first with a ceramic base such as Alumina and
Sensitive then with a final outer coating of Palladium or
bead Rhodium catalyst dispersed in a substrate
Signal Signal of Thoria.
Non-sensitive This type of sensor operates on the principle

bead that when a combustible gas/air mixture
passes over the hot catalyst surface,
combustion occurs and the heat evolved
increases the temperature of the ‘bead’.
This in turn alters the resistance of the
Platinum coil and can be measured by using
3 Wire mV Bridge Circuit
the coil as a temperature thermometer in a
standard electrical bridge circuit.
The resistance change is then directly related
to the gas concentration in the surrounding
atmosphere and can be displayed on a meter
or some similar indicating device.
36 www.honeywellanalytics.com/www.g
www.gasmonitors.com
Speed of
response
To achieve the necessary requirements of
design safety, the catalytic type of sensor 100
has to be mounted in a strong metal housing
behind a flame arrestor. This allows the
gas/air mixture to diffuse into the housing
% Response (Indicated)
and on to the hot sensor element, but will
prevent the propagation of any flame to
the outside atmosphere. The flame arrestor
slightly reduces the speed of response of
the sensor but, in most cases the electrical 50
output will give a reading in a matter of
seconds after gas has been detected.
However, because the response curve is
considerably flattened as it approaches
the final reading, the response time is often
specified in terms of the time to reach 90
percent of its final reading and is therefore
known as the T90 value. T90 values for
catalytic sensors are typically between 20 0
and 30 seconds. T60 T90 (TIME)
(N.B. In the USA and some other countries,

this value is often quoted as the lower T60
reading and care should therefore be taken
when comparing the performance of
different sensors).
Sensor
output
To ensure temperature stability under
varying ambient conditions, the
best catalytic sensors use thermally
matched beads. They are located in
opposing arms of a Wheatstone bridge
electrical circuit, where the ‘sensitive’
sensor (usually known as the ‘s’ sensor)
will react to any combustible gases
present, whilst a balancing, ‘inactive’
or ‘non-sensitive’ (n-s) sensor will not.
Inactive operation is achieved by
either coating the bead with a film of
glass or de-activating the catalyst so
that it will act only as a compensator
for any external temperature or
humidity changes.
A further improvement in stable

operation can be achieved by the use
of poison-resistant sensors. These have
better resistance to degradation by
substances such as silicones, Sulphur
and lead compounds which can rapidly
de-activate (or ‘poison’) other types of
catalytic sensor.
37
Principles of Detection (continued)
Typical types of gas sensor/transmitter
Sensor screwed to Sensor screwed to Sensor screwed to Transmitter with remote

Junction Box – two-man Transmitter with intrusive Transmitter with non-intrusive sensor – one-man
calibration one-man calibration one-man calibration non-intrusive calibration
Calibration
The most common failure in catalytic sensors Remember that where adjustments have designed to Intrinsically Safe (IS) standards,
is performance degradation caused by to be made within a flameproof enclosure, and with these it is possible to calibrate the
exposure to certain poisons. It is therefore the power must first be disconnected and a sensors at a convenient place away from the
essential that any gas monitoring system permit obtained to open the enclosure. site (in a maintenance depot for instance).
should not only be calibrated at the time of Today, there are a number of ‘one-man’ Because these sensors are IS, they can be
installation, but also checked regularly and calibration systems available which allow freely exchanged with the sensors needing
re-calibrated as necessary. Checks must be the calibration procedures to be carried replacement on site, with no need to shut
made using an accurately calibrated standard out at the sensor itself. This considerably down the system first.
gas mixture so that the zero and ‘span’ levels reduces the time and cost of maintenance,
can be set correctly on the controller. particularly where the sensors are in difficult Maintenance can therefore be carried out on a
to get to locations, such as an offshore ‘hot’ system and is much faster and cheaper
Codes of practice such as EN 60079-29-2 oil or gas platform. Alternatively, there are than early, conventional systems.
outline the legal requirement for calibrating now some sensors available which are
flammable gas detectors (%LEL) and also
guidance on the calibration of toxic gas
detectors (please note: toxic gas detectors
will have a legal requirement for calibration in
the future). Typically, checks should initially
be made at weekly intervals but the periods
can be extended as operational experience is
gained. Where two alarm levels are required,
these are normally set at 20-25%LEL for
the lower level and 50-55%LEL for the
upper level.
Older (and lower cost) systems require

two people to check and calibrate, one
to expose the sensor to a flow of gas and
the other to check the reading shown on
the scale of its control unit. Adjustments
are then made at the controller to the zero
and span potentiometers until the reading
exactly matches that of the gas mixture
concentration.
Infrared Gas Detector

Many combustible gases have absorption detected, whilst the other is not. The two
bands in the infrared region of the light sources are pulsed alternatively and
electromagnetic spectrum of light and the guided along a common optical path to
principle of Infrared (IR) absorption has been emerge via a flameproof ‘window’ and then
used as a laboratory analytical tool for many through the sample gas. The beams are
years. Since the 1980s, however, electronic subsequently reflected back again by
and optical advances have made it possible a retro-reflector, returning once more
to design equipment of sufficiently low power through the sample and into the unit.
and smaller size to make this technique Here a detector compares the signal
available for industrial gas detection products strengths of sample and reference
as well. beams and, by subtraction, can give a
measure of the gas concentration.
GAS
FACT
These sensors have a number of important
advantages over the catalytic type. This type of detector cannot
They include a very fast speed of response detect diatomic gas molecules
(typically less than 10 seconds), low and is therefore unsuitable Autoignition temperature
maintenance and greatly simplified checking, for the detection of of a flammable gas is the
using the self-checking facility of modern Hydrogen. temperature at which an
micro-processor controlled equipment.
ignition will take place,
even without an external
They can also be designed to be unaffected
spark or flame.
by any known ‘poisons’, they are fail-to-safety
(no fault that develops within the device can
result in a safety critical situation) and they will
operate successfully in inert atmospheres and
under a wide range of ambient temperatures,
pressure and humidity conditions.
The technique operates on the principle of

dual wavelength IR absorption, whereby
light passes through the sample mixture
at two wavelengths, one of which is set
at the absorption peak of the gas to be
39
Open Path Flammable

Infrared Gas Detector
Traditionally, the conventional method of The instrument continually compares the two
detecting gas leaks was by point detection, signals that are transmitted through the
using a number of individual sensors to cover atmosphere, using either the back-scattered
an area or perimeter. More recently, however, radiation from a retroreflector or more
instruments have become available which commonly in newer designs by means of
make use of infrared and laser technology a separate transmitter and receiver. Any
in the form of a broad beam (or open path) changes in the ratio of the two signals is
which can cover a distance of several hundred measured as gas. However, this design
metres. Early open path designs were is susceptible to interference from fog
typically used to complement point detection, as different types of fog can positively or
however the latest generation instruments negatively affect the ratio of the signals The use of Xenon flash lamps and solid state
are now often being used as the primary and thereby falsely indicate an upscale detectors makes the instruments totally
method of detection. Typical applications gas reading/alarm or downscale gas immune to interference from sunlight or other
where they have had considerable success reading/fault. The latest generation design sources of radiation such as flare stacks, arc
include FPSOs, loading/unloading terminals, uses a double band pass filter that has welding or lightning.
pipelines, perimeter monitoring, offshore two reference wavelengths (one either side
platforms and LNG (Liquid Natural Gas) of the sample) that fully compensates for Open path detectors actually measure the
storage areas. interference from all types of fog and rain. total number of gas molecules (i.e. the
Other problems associated with older designs quantity of gas) within the beam. This value
Early designs use dual wavelength beams, have been overcome by the use of coaxial is different to the usual concentration of
the first coinciding with the absorption band optical design to eliminate false alarms gas given at a single point and is therefore
peak of the target gas and a second reference caused by partial obscuration of the beam. expressed in terms of LEL meters.
beam which lies nearby in an unabsorbed area.
Maximum Intensity of Xenon discharge light Single reference design – fog interference
Sunlight
Filament lamp
Fog type 1 Fog type 2
Upscale Downscale
Detector output
gas/false alarm gas/fault
S R S R
Double reference design – fully compensates
Infrared Intensity
Fog type 2
Fog type 1
Solid state detectors

R S R
Older system lead salt detectors R S R
ElectrochemicalCellSensors
G
as specific electrochemical
sensors can be used to detect
the majority of common toxic
gases, including CO, H2S,
Patented Surecell™ Two Reservoir Design
Cl2, SO2 etc. in a wide variety of safety
applications. Housing
Electrochemical sensors are compact, require

very little power, exhibit excellent linearity and
Carbon filter
repeatability and generally have a long life
span, typically one to three years. Response
Working electrode
times, denoted as T90, i.e. time to reach
90% of the final response, are typically 30-60
reservoir
seconds and minimum detection limits range
from 0.02 to 50ppm depending upon target First small electrolyte
gas type.
Commercial designs of electrochemical cells Counter electrode

are numerous but share many of the common
features described below:
Three active gas diffusion electrodes are Second expansion

immersed in a common electrolyte, frequently reservoir
a concentrated aqueous acid or salt solution,
for efficient conduction of ions between the
working and counter electrodes.
GAS
FACT
Depending on the specific cell the target gas
is either oxidised or reduced at the surface
of the working electrode. This reaction alters
the potential of the working electrode relative Output pins If you smell the rotten egg
to the reference electrode. The primary aroma of Hydrogen Sulphide
from the decomposition of
function of the associated electronic driver
organic matter, you are
circuit connected to the cell is to minimise only smelling 1ppm.
this potential difference by passing current Just 1,000 ppm of H2S
between the working and counter electrodes, gas streams incorporate air as the major is enough to
the measured current being proportional to component or diluent. kill you.
the target gas concentration. Gas enters the
cell through an external diffusion barrier that Specificity to the target gas is achieved either
is porous to gas but impermeable to liquid. by optimisation of the electrochemistry,
Many designs incorporate a capillary diffusion i.e. choice of catalyst and electrolyte, or by Surecell™ design incorporates two electrolyte
barrier to limit the amount of gas contacting incorporating filters within the cell which reservoirs that allows for the ‘take-up’
the working electrode and thereby maintaining physically absorb or chemically react with and ‘loss’ of electrolyte that occurs in
“amperometric” cell operation. certain interferent gas molecules in order to high temperature/high humidity and low
increase target gas specificity. It is important that temperature/low humidity environments.
A minimum concentration of Oxygen the appropriate product manual be consulted
is required for correct operation of all to understand the effects of potential interferent Electrochemical cell sensor life is typically
electrochemical cells, making them unsuitable gases on the cell response. warranted for 2 years, but the actual lifetime
for certain process monitoring applications. frequently exceeds the quoted values.
Although the electrolyte contains a certain The necessary inclusion of aqueous The exceptions to this are Oxygen,
amount of dissolved Oxygen, enabling electrolytes within electrochemical cells Ammonia and Hydrogen Cyanide sensors
short-term detection (minutes) of the results in a product that is sensitive to where components of the cell are
target gas in an Oxygen-free environment, environmental conditions of both temperature necessarily consumed as part of the
it is strongly advised that all calibration and humidity. To address this, the patented sensing reaction mechanism.
41
Photo Ionised Detection (PID)
T
his type of detection principle The principle uses high-energy photons, output. This means that the higher the electrical
is often employed in portable which are usually in the Ultraviolet (UV) range current, the greater the concentration of the gas
gas detection solutions and is to break gas molecules into positively charged in the environment because when there is more
designed to deliver highly sensitive ions. When the gas molecules encounter the gas, more positively charged ions are produced.
monitoring of Volatile Organic Compounds UV light, the UV light is absorbed, resulting in
(VOCs) or other gases that need to be the ionisation of the molecules. This occurs PID gas detectors are popular due to their
detected in very small quantities, such as because the UV light excites the molecules, efficiency, low-level detection capabilities and
Chlorinated Hyrocarbons. resulting in the temporary loss of their cost-effectiveness (when compared to other
electrons and the subsequent formation of detection principles). Please see
A PID sensor can detect down to parts per positively charged ions. This process causes Portable gas detection on page 52 for more
billion (ppb), and this is necessary when the gas to become electrically charged and detailed information about PID detection
dealing with VOCs which can be highly toxic the current resulting from the positively suitability.
in very small quantities. charged ions acts as the gas detector’s signal
Chemcassette®
C
hemcassette® is based on the a wide variety of highly toxic substances, Then, as a stain develops, this reflected light
use of an absorbent strip of filter including Di-isocyanates, Phosgene, Chlorine, is attenuated and the reduction of intensity
paper acting as a dry reaction Fluorine and a number of the hydride is sensed by the photo detector in the form
substrate. This performs both as gases employed in the manufacture of of an analogue signal. This signal is, in
a gas collecting and gas analysing media and semiconductors. turn, converted to a digital format and then
it can be used in a continuously operating presented as a gas concentration, using an
mode. The system is based on classic Stain intensity is measured with an internally-generated calibration curve and an
colorimetry techniques and is capable of electro-optical system which reflects light appropriate software library. Chemcassette®
extremely low detection limits for a specific from the surface of the substrate to a photo formulations provide a unique detection
gas. It can be used very successfully for cell located at an angle to the light source. medium that is not only fast, sensitive and
specific, but it is also the only available
system which leaves physical evidence,
Photodiode i.e. the stain on the cassette tape that a gas
Signals to leak or release has occurred.
Microcomputer
3 LEDs
Detection specificity and sensitivity are
Sample in achieved through the use of specially
formulated chemical reagents, which react
only with the sample gas or gases.
As sample gas molecules are drawn through
the Chemcassette® with a vacuum pump,
they react with the dry chemical reagents and
Light reflected from form a coloured stain specific to that gas only.
tape surface The intensity of this stain is proportionate
to the concentration of the reactant gas,
Gas sampling head ie the higher the gas concentration, the
darker the stain. By carefully regulating
both the sampling interval and the flow rate
Gas stain on at which the sample is presented to the
Sample Exhaust Chemcassette® Chemcassette®, detection levels as
low as parts-per-billion, i.e. 10-9 can be
readily achieved.
Comparison of Gas Detection Techniques

Detection Catalytic ECC Point IR Open Path PID Semiconductor Paper Tape
Principle
Works in inert No (requires No (requires Yes Yes Yes No (requires No (requires
atmosphere presence of Oxygen) presence of Oxygen) presence of Oxygen) presence of Oxygen)
Resistant to Susceptible to Yes Yes Yes Yes Susceptible to Yes
poison poisons like Lead poisons like Halide
and Sulphur compounds, Silicone
containing vapours, caustic
compounds, and acid liquids
silicones vapours and concentrated
and phosphates vapours
Detects Hydrogen Yes Yes No No No No No
Performance in Yes Yes Yes Yes No Yes No

100% humidity
Performance in Yes Yes Yes Yes Yes Yes Yes
typical pressure
conditions
Performs in all Yes No (some models Yes Yes Yes No (some No (some
temperatures can be unstable models can be models can be
in low and high compromised below compromised below
temperatures) -40°C and above 10°C and above
90°C) 40°C)
Immune to Yes, with adequate Yes, with adequate Yes, with Yes, with Yes, with Yes, with adequate Yes, with adequate
dust/dirt weather and dust weather and dust adequate adequate adequate weather and dust filter and dust
protection protection weather weather weather protection protection
and dust and dust and dust
protection protection protection
Immune to Yes Yes Yes Yes Yes Yes No (decays tape)
sunlight
Performance Yes No (can alter Yes Yes Yes No (can alter No (detection of
in O2 enriched readings and readings and mineral acids is
atmosphere response) response) compromised in
Oxygen enriched
atmospheres)
Immune No No No No, e.g. poor No No No
to human alignment
interference
Speed of <20 secs <30 secs (typical) <6.5 secs <3-5 secs <5 secs <60 secs <10-30 secs
response
Maintenance High High Low Low High High High
requirement
43
11 Selecting Gas
Detection
There are many gas detection products on the market that might appear to be the
same, but a closer inspection of specification, functionality and features reveals major
differences in what products can do and the potential value they can offer. Similarly,
individual applications are also unique in their respective designs, needs and processes
undertaken.
Know your site risks Ask the right questions The gas detection vendor uses published
data to identify whether a gas is flammable,
toxic or an asphyxiant and the relative levels
B
efore beginning to consider Having identified the primary objective, the
gas detection equipment, a suitable equipment is selected by asking a at which it could cause a hazard. An ideally
risk assessment needs to be number of key questions. These fall into three suited gas detection solution aims to detect
conducted. Any company broad categories: and alarm prior to dangerous levels being
employing staff has the obligation to conduct reached. The same published data gives
risk assessments to identify potential hazards • The gases to be detected and where they information as to whether the gas or vapour
and these can include potential gas, vapour may come from is lighter or heavier than air, as this will affect
or Oxygen deficiency risks. If gas hazards are • The location and environmental conditions the selection of sensor positioning at the
identified, gas detection is applicable as a where detection is to take place points of detection.
risk reduction method. • The ease of use for operators and routine
servicing personnel It is also essential to identify the potential
Identifying the prime objective source of a gas release as this helps
The answers to these questions will have a determine the number and location of
Depending on the processes being direct impact upon the proposed solution and detectors required for a fixed gas detection
undertaken and the gases being detected, the associated costs to supply and maintain system.
remote or off-site alarm notification plus equipment.
event datalogging/reporting may also be In instances where the source of gas
release is not known, portable gas detection
required for Health and Safety management The gases to be detected and equipment, worn by site personnel may offer
records. Another factor impacting on the where they may come from
need for enhanced reporting functions might a better solution.
be regulatory compliance or a condition of The gases to be detected should be identified Some typical gas sources include:
insurance. by the risk assessment, however experienced
gas detection equipment manufacturers and • Natural occurrence, e.g. Methane and
Knowing the prime objective and motivation their approved distributors are often able to Hydrogen Sulphide from the
for having gas detection is the first step in help in this process, based on their experience decomposition of waste
selecting the best solution. of similar applications. However, it is • Leakage for a supply pipe or storage tank,
important to remember that it is the end-user’s e.g. piped Natural Gas supplies
responsibility to identify all potential hazards. • Emissions from a combustion process,
e.g. Carbon Monoxide from an exhaust or
a boiler flue
• Emissions from a production process,
e.g. solvents in the printing and coating
industry
• Emissions from a manufacturing plant,
e.g. Ammonia from a refrigeration plant or
Nitrogen from a Nitrogen supply plant
integrated into a separate safety system,
certain communication protocols may also
be required such as HART®, Lonworks
or Modbus®. Please see Communication
protocols on page 48 for more detailed
information.
Consideration will also need to be given

regarding the requirement for local displays
on transmitter units and local configuration
of the unit and gas displays may also be a
useful addition.
A holistic approach needs to be adopted

when looking at the functionality of a device.
There are a large number of variations with
products and as you would expect, there
is often a cost implication with increased
functionality. Again, this is where working
with a gas detection specialist can help by
identifying the additional spec that could be
valuable. Things like local displays, local user
interfaces, software compatibility, the number
of relays and outputs required, remote sensor
mounting capabilities, on-board diagnostics,
cartridge hot swapping and event logging
abilities provide additional benefits to the user
and make one product more applicable than
another.
Consider the environmental chosen. For example, there may be other
elements such as Hydrogen Sulphide, which
conditions The ease of use for operators
have corrosive properties or other airborne
The performance, accuracy and reliability
compounds which could have an adverse androutineservicingpersonnel
affect upon the reliable operation of some
of any gas detection equipment will be
sensing technologies, e.g. Silicones poisoning Routine maintenance is another important
affected by the environmental conditions
catalytic bead sensing technologies. consideration. Some gases and vapours
it is subjected to. Temperature, humidity
and pressure levels at the location all have can be detected with a number of different
Another important consideration is a device’s sensing technologies, e.g. Hydrocarbon
a direct bearing on the type of equipment
suitability for use in certain hazardous gases with catalytic beads or Non-dispersive
that should be selected. Additional factors
locations. Hazard areas are classified Infrared NDIR. Catalytic beads do not
such as potential variations resulting from a
according to their perceived likelihood of provide fail-to-safety operation and therefore
production process itself, diurnal/nocturnal
gases being present. It’s important that a can require a high frequency of routine
fluctuations and seasonal changes may also
device cannot ignite a gas cloud. With this in maintenance, however NDIR based solutions
affect the type of device which is suitable.
mind equipment that is Intrinsically Safe tend to have a higher initial purchase price,
It is important to consider whether the
(Ex ia/Ex ib) or Explosion-Proof (Ex d) has but may require less routine maintenance.
equipment will be used inside or externally
been created to provide enhanced safety. In-house resource to undertake such routine
as this can greatly affect the design of the
Please see Area classification on page 86 for maintenance needs to be identified and in the
device. For example, an external location
more detailed information. absence of such a resource, budgeting for
that is exposed to elements such as wind,
rain and salt spray, will require equipment third party maintenance is an important
A competent gas detection equipment factor in selecting the right equipment.
which is resistant to the corrosive effects of
supplier will have a range of different sensing
that environment. Although indoor locations
technologies available that can be applied Detection equipment downtime during
typically require less robust housing,
to a given application. In addition, the routine sensor replacement can lead to the
consideration should be made for internal
environmental conditions start to determine loss of production. If this is a concern, some
areas which are hosed down on a frequent
the best mechanical configuration of the final solutions can provide a fast, simple and safe
basis. In locations where water/moisture, dust
solution. method of sensor exchange without needing
and dirt are prevalent it’s important to get a
device that is protected by water/dirt ingress. to down-power the system or the plant.
Please see Ingress protection of enclosures Product functionality
on page 92 for more detailed information. A good gas detection equipment supplier
The next area of consideration relates to should be able to offer a range of service
Aside from natural environmental conditions additional product functionality. Aspects packages to help maintain equipment.
such as weather, there may be other materials like wiring configuration are important, Please see Gas detection maintenance
in the environment that can have a potential especially when retro-fitting into an existing and ongoing care on page 106 for detailed
affect on the type of equipment that is application. If the apparatus is being information on looking after equipment.
45
12 Maximising time
and efficiency
“Smart” functionality may mean different things to different people and encompasses
much more than just a device’s features and in-built intelligence. The smartest solutions
are those that provide efficiency and cost-effectiveness over the whole product life.
D
evices with firmware are often situated; this means that the application normal operation, yellow to indicate a fault
seen as being “smarter” than itself, environmental factors and additional status and red to indicate an alarm status.
traditional analogue systems elements the device could come into contact Although there are many models on the
because they may be able to with, all impact upon whether one device market that offer tri-colour LCD indicators,
self-diagnose, improve accuracy, and possibly is really a “smart” choice after all. In some the Sensepoint XCD range provides a full
decrease the amount of time spent calibrating cases, non-intelligent devices may be a better colour-illuminated screen that is easily
or maintaining the device. Today more than choice for an application. This is highlighted seen from a distance. An example of the
ever, businesses are concerned with reducing by the divide in the global petrochemical cash saving this functionality could actually
costs and maximising efficiency and the choice industry with different regions adopting translate into can be illustrated by the
of a smart solution can result in considerable different technologies. following example: Consider a plant set-up,
savings over whole product life. where a series of devices are monitoring for
Functionality doesn’t necessarily have to be gas hazards and are feeding back information
This does not necessarily mean that a device intelligent to make a big impact. to a Programmable Logic Controller (PLC). If
can only save you money if it features The Sensepoint XCD range from a hazard occurs, the maintenance engineer
in-built intelligence. Products can only be Honeywell Analytics features a tri-colour must enter the area, and find the sensor
properly evaluated within the context of display that clearly indicates the unit’s status that has gone into warning/fault. If the plant
their subsequent use and where they will be at a glance – even from a distance; green for is large with many points of detection,
Field time can also be reduced because
this could take some time. In the case of Smart sensor and calibration
Sensepoint XCD, the device in warning/fault devices that have been inhibited so field
philosophies work can be carried out on them, do not
will be clearly visible by its bright illuminated
screen, meaning that the engineer can get need to be manually put back online by a
Ease of sensor swapping and calibration can
straight to the unit and the simplicity of the second employee working in a control room;
also deliver savings. This can be highlighted
colour coding means that the device’s status they can be set to automatically go online.
by the auto recognition “Plug and Play”
is instantly accessible with a simple glance. This functionality also limits the occurrence
sensor capabilities of devices like Apex from
of nuisance false alarms that can adversely
Honeywell Analytics, which use smart
Aspects like Sensepoint XCD’s tri-colour impact on a plant’s production.
pre-calibrated sensors. These sensors can
display screen are not necessarily “smart” in
be taken out into the field and changed over
their own right, but as the example highlights,
in just one minute.
The value of common design
the resulting impact they can have in saving
time and subsequent costs may well make Today’s devices are being built with not
This means that the change out of 100 Apex
them a “smarter” choice over a comparable only functionality in mind but also a smarter
sensors would take just under two hours to
solution. In addition, the device’s display approach to product design; aspects such as
complete compared with a standard sensor
also negates the need for additional expense common device and spare parts design enable
technology where each device could take
associated with integrating local status lights, businesses to carry less spares. As an industry
up to 20-30 minutes to change out and
providing a cost saving. average, 2-5% of the total order is required
re-calibrate (equating to 3 ½ days labour
as additional spares stock. Spares stock can
by comparison).
Save time... save money also be reduced through the use of common
design devices like XNX Universal Transmitter.
Speculate to accumulate Typically using XNX Universal Transmitters, the
The most cost-effective systems are those
that permit quick and easy use of the device value of the overall system cost attributable to
The saying “you get what you pay for” often
and minimal training. Even a small reduction spares stock can be reduced to one-third of
rings true, meaning that more intelligent
in the time required on each device – just a that of a conventional system utilising separate
devices and those that deliver enhanced
few minutes – can quickly translate into big transmitter types. This is achieved through the
functionality tend to have a higher purchase
cash savings, as the following hypothetical removal of the need to carry different types of
price. But often this money can be recouped
example highlights: Consider a site that has spares for the various transmitter types that
many times over as can be highlighted by
100 catalytic bead driven devices; if each may be installed.
the savings that automatic datalogging can
unit takes 10 mins to check and re-calibrate have on a site’s labour cost. A gas and fire
using one solution compared with 6 mins per Another value aspect of devices that use
controller that can carry out regular automatic
device using another, a saving of 37% on common design and intuitive user interfaces is
datalogging may cost $500 more (for
labour costs is achieved just by saving that they reduce the chance of incorrect set-up or
argument’s sake) than a controller that cannot
4 minutes per device. calibration, which can lead to nuisance alarms.
offer this functionality. A site that wishes to
Just one nuisance alarm that causes a required
datalog every hour will need an engineer to
Products like the Sensepoint XCD range process shutdown of 60-90 minutes at a site
undertake this work manually, if an automatic
a
and the XNX Universal Transmitter from producing 1,000 barrels of oil per hour, can
facility is not available. If each datalog check
H
Honeywell Analytics provide complete equate to 1,500 barrels of lost oil production.
takes 15 mins to complete, this means that
m
monitoring solutions for flammable, toxic and in a 16 hour day (many plants operate two
Oxygen
O gas hazards and they also feature eight hour shifts per day), 4 hours will be
A Case by Case approach
the
th same interface and calibration methods. required to make the relevant checks. By the
This
T means that operators do not need to be Local factors and individual plant set-up will
time the device has been used for a year, the
trained
tr to use each variant separately. This is have a large impact on whether one device
purchaser will have saved around 208 hours
particularly
p valuable as plants can evolve and is more suitable than another in terms of
in labour.
processes
p can change, meaning additional providing a cash saving. It’s important to
gas
g detection solutions may be required. work with a supplier who can provide multiple
The same can be said of aspects like
Using
U devices like these mean that training technologies and specification variance,
intelligent communications platforms such as
c be minimised and when you consider
can as this will enable them to give impartial
HART®, Modbus® and LonWorks that facilitate
th training fees, expenses to get personnel
the guidance on choosing the right solution that
enhanced two-way communication between
to the location where training is situated and is truly fit-for-purpose, based on your
the device and the control system. This type
a
also any cost implications resulting from individual variables.
of functionality has many potential benefits
a
additional personnel cover whilst training of like assisting with planned maintenance
o group is taking place, this can provide
one activities, allowing operators to schedule
n
notable savings. maintenance and improve time efficiency as
well as ensure maximum equipment uptime.
A minimisation of production loss can save
Any For sites using a 4-20mA infrastructure,
m
money. Consider a site that uses a device HART® can deliver enhanced communications
li Sensepoint XCD Remote Flammable
like without the need for additional cabling, and
D
Detector (RFD) to monitor for Methane gas in considering that cabling is the single biggest
a potentially explosive environment. cost for any site, this is highly valuable.
T device’s ability to provide useful warnings
The Please see Communications protocols on
th indicate the need for maintenance can
that page 48 for more detailed information.
h
help to reduce nuisance alarms.
47
13 Communications
Protocols
Communication is essential in all areas of life – and gas detection is no exception.
ion.
In fact, the application of communication capabilities to smart field devices and
d
process monitoring technologies is able to bring valuable dimensions to site safety.
afety.
S
afety control systems are usually
a
organised with a hierarchical
system of three core levels
of hardware and software.
The highest level is represented by the
Human Machine Interface (HMI), which is s
often a PC based solution. This allows an n
operator to interact and monitor the system,
e
using protected passwords allowing for
acknowledgement and/or modification
Today Foundation Fieldbus™ co-exists with Honeywell Analytics
as needed. The second level down is the
Modbus®, Profibus® and Industrial Ethernet released its own digital
Programmable Logic Controllers (PLCs).
(an ethernet concept that offers enhanced system in 1985 called
These allow signals from analogue, digital
data checking and stability). Gas Data Acquisition and nd
and bus to interface with the HMI. The
Control System (GDACS), S),
tertiary level consists of the devices such as
The plethora of options available is brought ocol.
using a proprietary protocol.
Infrared (IR) gas detectors, toxic sensors,
about by the varying needs of industry when It was created to offer
pressure and temperature sensors and flow
it comes to communication. Some protocols ced
flexibility and an enhanced
measurement field devices.
offer peer-to-peer communication (such as level of interaction to its users, and its value
Foundation Fieldbus™), meaning that the PLC has stood the test of time. In fact, today
The type of communication protocol
is always receiving streamed data as well as Honeywell Analytics still supports customers
employed by the system to interface between
being able to request information from the using this protocol.
the PLCs and field devices will determine
device. Others (such as HART®) work on a
the type of data that can be obtained from
master-slave principle where data is not being Communications protocol
a device and the frequency with which that
streamed continuously and the PLC (acting
data can be transmitted or received. Many
as master) requests the information from the
value
PLCs tend to use a 4-20mA input.
slave device, which in turn sends data back
Communications protocols offer considerable
to the PLC.
Communications value, helping to improve safety, simplifying
maintenance and reducing ongoing costs:
protocol types HART® actually operates with two master
functions; a Primary Master (such as a
• They can allow the user to access
The concept of gas detection with PLC or Distributed Control System (DCS)
information from the smart field device
communications capabilities is not a and a Secondary Master (such as a
(such as gas readings, signal level,
new one; in fact, gas detectors have HART®-enabled hand-held device); this
raw sensor readings and temperature)
been using protocols like provides the user with additional value.
• They can allow a user to change
Foundation Fieldbus™, Modbus®, Profibus® For example, an operator can go out into
calibration and device configuration
and Highway Addressable Remote the field with a HART®-enabled handheld
• They can help to facilitate proactive,
Transducer (HART®) since the 1980s. interrogator or can use a PLC/DCS situated
scheduled maintenance over reactive
in a control room or another area.
maintenance
Since the inception of communication
• They can reduce ongoing costs because
protocols, many variants have emerged, with Modbus® RTU has been very popular for the
proactive maintenance is less costly than
Modbus® being the first to be developed in last 20 years. This is due to the speed with
reactive
1979. Foundation Fieldbus™ was a protocol which it can transmit data and the fact it
• They can reduce field engineering costs,
released in the 1980s and was strongly features an error check mechanism to ensure
because device communication allows you
adopted in the USA. Profibus® soon emerged the reliability of data being sent and received,
to “know before you go”, meaning that an
as an alternative to Foundation Fieldbus™ and and continues to be popular due to Modbus®
engineer can be prepared for work
became popular in Europe. TCP/IP over Ethernet.
needing to be undertaken in the field.
most widely adopted communications detection needs. This helps to reduce costs
protocols, and is used by approximately and simplify operation considerably.
30 million devices Worldwide.
XNX Universal Transmitter is an extremely
HART® allows a PLC to issue three types flexible solution that can be configured to
of command: a Universal command for accept an input from any of the
data, which all HART® field devices respond Honeywell Analytics range of gas sensor
to, a Common practice command, which technologies (IR Open Path, IR Point, high
many devices will use and a Device specific temperature sensors, electrochemical cell
command, which is unique to a particular and mV), providing one single interface
device. A Device Description (DD) file is solution to all flammable, toxic and gas
produced by a manufacturer of a monitoring
it i on site. The d
it Th device
i also
l offers
ff
Trends and the popularity HART®-enabled field device, and it allows a wide variety of output signals including
of HART® the user to interact directly with a device HART®, Foundation Fieldbus™, Modbus®,
such as Searchpoint Optima Plus from 4-20mA and relays, delivering the flexibility
Communications protocols all work in slightly Honeywell Analytics. This allows the user to meet the demands of a wide variety
different ways and for this reason, they offer to poll the device for information and any of industries and applications including
varying benefits and disadvantages over each procedures specific to that device anywhere onshore and offshore oil and gas, power
other. Peer-to-peer communication protocols in the loop, using a HART®-enabled stations and chemical and petrochemical
such as Foundation Fieldbus™ require more hand-held that includes the DD file from plants.
power because of the extra data being Honeywell Analytics.
constantly streamed from the device to the When this value is combined with the
PLC, but conversely they offer the additional The true value of HART® becomes apparent benefits facilitated by HART®, the ongoing
benefit of allowing constant communication in the context of a specific product such as cost of gas detection can be reduced further.
from the field device to the PLC, which is Searchpoint Optima Plus. In essence, there HART®-enabled, universal-use field devices
essential for many regulated processes. are two core areas that a site can benefit from like the XNX Universal Transmitter are
HART®; commissioning/set-up and ongoing likely to grow in popularity, thanks to their
HART® is becoming an ever-more popular maintenance/operational efficiencies. functionality and cost saving potential.
communication protocol owing to the fact
that it communicates over a legacy 4-20mA
analogue wiring topology; the digital HART® HART® and universal device
signal is superimposed over the existing
4-20mA signal and permits bidirectional
use: a winning combination
GAS
communication, which allows the operator the
flexibility to make device modifications using
the HART® signal. Infrastructural costs like
The advent of “one size fits all” devices like
the XNX Universal Transmitter from
Honeywell Analytics are very much in-line
FACT
There are 17 gases in total,
wiring are one of the most expensive aspects with market needs; in fact the perfect solution which can be found in the
of a plant, so this ability makes HART® highly for most end-users is a universal device that natural atmosphere on Earth.
can interface with most existing gas sensing Only Oxygen and Nitrogen are
attractive to many sites. In fact, its growing
found in large concentrations;
popularity highlights the large global install technologies on site, providing one simple, 20.9476% and 78.084%
base of 4-20mA wiring. Today it is one of the long-lasting solution to ever-changing gas respectively.
49
14 Fixed gas
detection from
Honeywell
Honeywell Analytics produces a Sensepoint XCD Sensepoint High Temperature Sensor
comprehensive range of flammable, toxic Flammable, toxic and Oxygen Ideal for combustible gases in
and Oxygen gas detectors, with options transmitter and sensor with high temperature areas
designed to meet the needs of all industries tri-colour display for viewing
and applications; from low-cost compliance status from a distance
through to high-end solutions that minimise
maintenance and maximise equipment Fixed Gas Detection (Toxic)
uptime. Searchline Excel
World renowned open path IR Vertex M
detector with 200m dynamic Cost effective, 8-24 point toxic
monitoring range gas monitoring with physical
Honeywell Analytics evidence of a leak
Experts in Gas Detection Apex
High performance flammable VertexTM
and toxic detector with a choice Flexible device providing
Fixed Gas Detection of communications platforms continuous monitoring of up to
(Flammable and Toxic) 72 points
XNX Universal Transmitter

Searchpoint Optima Plus
A universal transmitter
Market leading point IR
compatible with all
detector with 100 gases
Midas®
Honeywell Analytics gas Sensitive detection using smart
available. Optional HART®
sensor technologies sensor cartridges and Power
over 4-20mA output
over Ethernet (PoE)
Series 3000 MkII and MkIII

2-wire loop powered toxic Signalpoint Range
Low cost range of flammable,
and Oxygen gas detectors for Chemcassette®
use in potentially explosive toxic and Oxygen gas detectors
Calibration-free toxic gas
atmospheres detection with physical
evidence of a leak
Sensepoint XCD RFD Signalpoint Pro

A flammable gas transmitter Low cost range of flammable, Satellite XT
for use with remotely mounted toxic and Oxygen gas detectors Small and compact toxic gas
flammable gas sensors with integral gas concentration detection with a wide range of
display sensors
Sensepoint XCD RTD Sensepoint Range

A gas transmitter for use with Low cost ATEX certified Sat-Ex
directly or remotely mounted flammable, toxic and Oxygen Comprehensive monitoring of
toxic and Oxygen gas sensors gas detectors corrosive, combustible and toxic
gases in potentially explosive
atmospheres
SPM Single Point Monitor
A fast response device
detecting in the ppb range with
physical evidence of a leak
ACM 150 FT-IR

Versatile and sensitive detection
of up to W40 points with many
gases available
CM4
Low cost continuous monitoring
of up to four detection points
with minimal maintenance
requirements
Controllers
System 57
Precision controller accepting
inputs from toxic, flammable,
Oxygen, flame, smoke and
heat detectors
Touchpoint 1
Flammable, toxic and Oxygen
controller for use with the
Sensepoint range of
gas detectors
Touchpoint 4
Flammable, toxic and Oxygen
controller for use with the
Sensepoint range offering
4 points of detection
Unipoint
DIN rail mounted controller
offering flexibility at low cost
51
51
15 Portable Gas
Detectors
Flammable and toxic gas detection instruments are generally available in two different
formats: portable, i.e. ‘spot reading’ detectors and ‘fixed’, permanently sited monitors.
Which of these types is most appropriate for a particular application will depend on
several factors, including how often the area is accessed by personnel, site conditions,
whether the hazard is permanent or transitory, how often testing is needed, and last but
not least, the availability of finances.
P
ortable instruments probably
account for nearly half of the total
of all modern, electronic
gas detectors in use today.
In most countries, legislation also requires
their use by anyone working in confined
spaces such as sewers and underground
telephone and electricity ducts. Generally,
portable gas detectors are compact, robust,
waterproof and lightweight and can be easily GAS
FACT
carried or attached to clothing.
Portable gas detectors are available as single

or multi-gas units. Single gas units contain Hydrogen Sulphide bubbling
one sensor for the detection of a specific gas, up from the sea may have
whilst multi-gas units usually contain up to
caused a global extinction of
flora and fauna nearly
six different gas sensors (typically Oxygen,
250 million years ago.
flammable, Carbon Monoxide and
Hydrogen Sulphide).
Products range from simple alarm only

disposable units to advanced fully
configurable and serviceable instruments
with features such as datalogging, internal
pump sampling, auto calibration routines and
connectivity to other units.
Recent portable gas detector design

advances include:
• The use of more robust and lightweight

materials for construction
• The use of high power microprocessors,
enabling enhanced datalogging and
self-checking etc
• The employment of modular designs
that allow simplified routine servicing and
maintenance
• Battery advancements providing extended
operating time between charges and a
smaller battery pack.
53
Portable Gas Detectors (continued)
Why are portable gas

detectors so important?
Portable gas detectors are classed as a type Although fixed gas detection does provide This choice may be made for the following
of Personal Protective Equipment (PPE), personnel protection in its own right, it cannot reasons:
designed to keep personnel safe from gas move with the operator, and this creates the • The area may not be entered by personnel
hazards and allow mobile testing of locations possibility that the operator could enter an very often, making the addition of fixed gas
before they are entered. area beyond the detection perimeter of the detection cost-prohibitive
fixed detector. • The area may be small or hard to reach,
These small devices are essential in many making the placement of fixed gas
areas where gas hazards could occur, Many sites employ a mix of both fixed and detection impractical
because they are the only means of portable gas detection, but sometimes • The application requiring detection may
monitoring an operator’s breathing zone portable gas detection is used on its own. not be stationary itself. For example, when
continuously, whilst stationary and moving. a Liquid Natural Gas tanker is offloading its
cargo at the dock, the dock will be
stationary, whilst the tanker itself will be
moving due to the motion of the sea
KEY
Detection
capability
of devices PROCESS AREA 2 PROCESS AREA 1
S
G GA
N
TI
PORTABLE
RA
Monitoring likely
MIG
sources of a leak
FIXED (joints and seals)
Spurious fissure in pipework
causing a leak
FIXED As the operator moves towards the

migrating gas, the device will alarm FIXED
and alert them to the spurious leak
FIXED
FIXED
Breathingzone
The breathing zone is defined as the Defines
Example of
25 cm/10 inch radius of an operator’s mouth breathing zone
portable gas
and nose. A portable device can be fixed in detector
positions
various locations within the breathing zone
Hat clip
including being fastened to jackets or to
breast pockets (but never inside a pocket),
or held in place by a harness/hat clip.
25 cm/10 Inch radius
It’s essential that the device is secure at from this point
all times.
Typical gases
requiring
portable
detection
Harness
There are diverse applications and
environments that require portable gas
detection monitoring and numerous toxic and
flammable gases may be encountered.
The most commonly detected gases include:
• Carbon Monoxide Enhancing

•
•
Carbon Dioxide
Hydrogen Sulphide safety with
portable gas
• Oxygen depletion
• Flammable gases such as Methane,
Liquid Petroleum Gas and
•
•
Liquid Natural Gas
Ammonia
Sulphur Dioxide
detectors
• Chlorine Changing legislation and regulatory
• Chlorine Dioxide compliance, combined with evolving
• Nitrous Oxide insurance pre-requisites are making the use
• Nitrous Dioxide of portable gas detectors more prevalent in
• Phosphine many industries.
• Hydrogen Cyanide
• Ozone There is a big drive within many sites to
• Various Volatile Organic Compounds “enhance safety” and the integration of a
(VOCs) including Acetone, Benzene, portable gas detection fleet on site is one way
Toulene and Xylene of assisting with this.
Due to the variety of applications and different In addition to legislated requirements (where
processes undertaken, many additional gases compliance is mandatory), many sites also
may also be detected by portable devices. choose to implement site-specific rules; for
Please see Typical applications for portable example bump testing a portable gas detector
gas detectors on page 60 for information on before it is used by any operative. Please see
which gases are likely to be found in specific Maintaining portable gas detection on page 72
applications. for more information on device testing.
55
Portable gas Operational modes of a

detectortypes portable gas detector
There are two primary types of portable Portable detectors can draw air in (known as sampling) or they can allow air to
gas detector: diffuse into the sensor, depending on the application needs:
• Single gas – devices that are designed • Diffusion: This is the mode that the portable device will be in the majority of
to detect one gas the time it is being used for personnel breathing zone monitoring. As an
• Multi-gas – devices that can detect operator enters an area where a concentration of gas is located, the gas will
multiple gases. Variants usually range need to reach the sensor and diffuse into it for the detector to “see” the gas
from 4 gases up to 6 gases and tend to • Sampling: An integrated motorised pump or sample kit, which includes a
employ various detection principles in hand aspirator, can allow a device to draw air towards the sensor. The ability
one unit to sample the air - either manually or using a motorised pump - is safety-critical
when an area may contain hazards, because it allows an operator to check the
When it comes to ongoing device operation and air for gases before entering and breathing the air in.
maintenance, portable detectors fall into two further
groups:
The following picture shows two examples of BW Technologies by Honeywell’s portable
solutions – a single gas disposable device and also a multi-gas detector. Products are
• Serviceable – this means that the device
shown at actual size.
is a long-term solution, requiring ongoing
maintenance, which the operator can
choose to carry out in-house or via a third
party service provider
• Disposable – this means that the device
Multi-gas
is a short-term solution (2 or 3 year) GasAlertMicroclip XT
and does not require any maintenance IntelliflashTM visual
during its operational life. This type of compliance indicator
device is often continuously operational
from first activation until its expiry.
Single gas Usual alarm indicators
GasAlertClip Extreme
Display
Button operation
Sensor Sensors
(gas diffuses in here) (gas diffuses in here)
GasAlertClip Extreme dimensions

Dimensions 2.8 x 5.0 x 8.1 cm / 1.1 x 2.0 x 3.2 in.
GasAlertMicroclip XT dimensions
Dimensions 11.3 x 6.0 x 2.9 cm / 4.4 x 2.4 x 1.11 in.
Features and
functionality
Due to the diversity of applications and the
hazards that are contained within them,
the specification for portable gas detectors
varies considerably.
The key functionality/specification aspects a

portable device delivers and its associated
value is detailed in the table below:
Aspect Description Value

Display The addition of a display allows the operator to see Safety can be enhanced because an operator can see a rising gas value before the alarm
the monitoring results of the detector. Many devices is sounded. A display can also provide peace of mind to an operator, through the display of
feature a real-time display and this means that the “correct operation” icons and aspects like the gases being detected and how many days
device visually shows gas values to the operator as until the next calibration. When it comes to disposable devices, a display can also advise of
well as other operational icons. how many operational months are left.
Device protection (also known as The Ingress Protection (IP) rating (please see page A device that is impact resistant and capable of being submerged in water will provide a
Ingress Protection) 92 for more information) and impact resistance flexible monitoring solution that can adapt to many application needs on site. In fact, water
of a device indicates its suitability in challenging treatment and offshore applications require this protection. It also helps to ensure the
environments where water, dust, dirt and other longevity of a device.
materials may be located.
Button operation Some devices (including those provided by Large, single button operation allows an operator to work with the device more easily and
Honeywell), use large, single button operation also means that he/she does not need to remove gloves to activate the buttons. This can
designed to provide simplified interaction. Other save considerable time over product life.
devices may feature multiple buttons.
Integrated datalogging An integrated datalogging capability means that any Integrated automatic datalogging helps to simplify and assist time-effective event reporting.
event (such as an alarm), is automatically stored in It is also important to remember that many insurers stipulate detailed reporting.
the device and can be downloaded later and used
for reporting purposes by a portable fleet manager.
The amount of data that can be logged will vary from
device to device.
Battery performance Battery type, run time and also charge time can vary A high performance, quick charge battery can provide the flexibility to cover long shifts or
considerably from device to device. multiple shifts without needing to be re-charged. A shorter charge cycle can also reduce the
number of portables required on site and the power consumption required over product life
to charge devices.
Sensor integration types Some devices allow individual sensors to be added Both aspects have their merits: the former allows flexibility in terms of being able to update
or removed, whilst others use an integrated sensor one sensor if needed, but keeping other sensors intact. Conversely, an integrated sensor
cartridge. cartridge provides a quick and simple means of replacement, thus reducing the time and
cost of maintenance over product life.
Motorised sampling pump A motorised pump allows a device to draw air from a Applications like confined spaces need to be tested before they can be entered. Testing
potentially hazardous area without having to enter it. using a device that can switch between diffusion and sample mode can save time over
Some devices feature integrated motorised pumps, using a manual sample kit, which needs to be fitted to the device. The flow of air is also
whilst others don’t. regulated with a motorised pump.
Alarms Most devices feature visual, audible and vibrational It’s essential that a device can get attention – even in high noise locations – so the use
alarms to alert operators to hazards. of multiple alarm types helps to ensure that an alarm event is never missed. Honeywell’s
portable gas detectors feature ultra-bright, wide angled alarms that can be seen easily,
supported by loud audible and vibrational alarms that are guaranteed to demand attention
in any application.
Visual compliance indicators Some devices, like those from This aspect can improve site safety and assist considerably with fleet management activities
BW Technologies by Honeywell, feature special visual because it makes non-compliant devices easier to spot, prompting operators to ensure their
indication LEDs that are automatically de-activated device is maintained in accordance with site standards.
when the device is overdue for calibration or
bump testing.
57
Accessories
Portable gas detectors come with a wide Accessories designed to Accessories for power and
range of accessories, which fall into the
protect devices against water, charging
following categories:
dust and dirt ingress
Sites can have varying shift lengths so it’s
Accessories designed to important to choose the right power solutions
Many applications requiring gas detection
secure portable devices: may be dirty, full of airborne particulates, that can meet requirements. Sometimes a
dusts and water. If the unit is not properly number of operators may share a device,
It’s essential a portable gas detector is always so there might not always be time to fully
protected, these elements can get into the
securely fastened within the breathing zone. charge between shifts. Car charging kits and
device’s sensor and prevent it being able
Many jobs demand the use of both hands, cradles provide easy charging on the move
to detect gas properly, which can be very
and there are various options available for operators who travel.
dangerous. Additional protection can be
that allow a unit to be securely fastened
provided by filters designed to prevent debris
comfortably. • Various battery options including Alkaline
and water from getting into the unit and
compromising its detection capabilities. or Lithium batteries
• Lanyards/neck straps in various lengths, • Rechargeable battery packs
which allow the operator to wear a • Vehicle charger adapters
• Sensor protection filters (including
portable securely around his/her neck • Cradles and accompanying chargers
hydrophobic and particulate)
• Hard hat clip allowing the device to be
• Water floatation aids
secured to the side of a hard hat
• Harnesses securing the device to the
chest or other area of the body
Accessories designed to
facilitate air sampling Accessories for datalogging
If a gas hazard could potentially be present When datalogging directly to a PC or laptop
in an area that an operator is planning on is required, USB-based readers provide a
Accessories designed to entering, the air should be sampled first, quick and simple means of downloading data.
protect devices using a kit or pump that allows the air to be Multi-media cards also allow additional data
drawn. Entering an area without carrying out to be stored and held on compatible devices.
Although many units are deigned to be this test could result in death; especially when
“concussion proof” an accidental drop highly toxic gases could be present. Just one • USB memory card readers
can cause damage which could either breath of 1000ppm of Hydrogen Sulphide is • Multimedia cards
compromise the unit’s ability to detect gas enough to kill.
and alert to a danger or could limit the
operational life of the unit and make ongoing • Manual hand aspirator
maintenance difficult. Additional protection • Probe and flow tubing
can be used when working in challenging • Test cap (allowing only sampled air to be
locations. drawn into the sensor)
• Pump module (a device that fits over the
• Concussion proof boot unit’s sensors and allows air to be drawn)
• Carrying holster • Honeywell produces integrated sampling
• Vehicle attachment kits and confined space entry kits for its
full range of portable gas detection
products
Alarms and status indication

Alarm types As previously mentioned, a portable unit can be
used in two key ways; to monitor the breathing
A portable gas detector can be configured to zone of an operator (diffusion mode) or to
alarm in various conditions, so that it can alert pre-check an area before an operator enters a
operators to certain hazard states. location that could contain hazardous gases.
The purpose of an alarm is to indicate an Portables are particularly important when

impending danger before it becomes operators are working in areas where toxic
safety-critical or dangerous to health. gases are present that they can be exposed
Please see page 21 for detailed information to for limited amounts of time and in limited
on Workplace Exposure Limits (WELs). concentrations. STEL and LTEL alarm types
provide this protection and alert the operator
• Short-term exposure limit (STEL) when maximum exposure levels are reached.
(15 min duration)
• Long-term exposure limit (LTEL) Value-added visual status
(8hr duration) indication
• Low level alarm: This defines the low
alarm set point The range from BW Technologies by Honeywell
• High level alarm: This defines the high also provides an additional value-added
alarm set point visual indicator that can enhance site safety
considerably. IntelliFlashTM, provides a clearly
Most portable gas detectors feature three visible green LED indicator to show device
alarm types – audible, visual and vibrational compliance to site-standards. When a device
– designed to alert the operator to an alarm is not maintained correctly, the IntelliflashTM
event, even in high noise areas, or when the indicator will switch off, highlighting device
portable gas detector is attached somewhere non-compliance to the operator and also the
that the visual alarms cannot be seen (such fleet manager.
as fixed to a hard hat).
59
Typical applications for

portable gas detectors
Confined spaces There are two types of confined space: Confined space types
Confined spaces can be found in a myriad • A normal confined space Confined spaces can be found in a wide
of industries and applications and are one of (no permit required) diversity of industries and applications.
the most prevalent applications for portable • A permit-required confined space Common types include:
gas detection. A confined space is defined as
being: In addition to the criteria defining a standard • Shafts
confined space, a permit-required confined • Trenches
1. A space that has a limited or a restricted space will also have one or more of the • Sewers and manholes
means of entry/exit following attributes: • Pits
2. A space that is large enough for an • Boilers
operator to enter and perform certain • Is known to contain (or has contained) a • Tunnels
tasks hazardous atmosphere • Tanks
3. A space that is not designed for constant • Is known to contain a recognised safety • Vessels (including marine vessel tanks)
worker occupancy hazard • Pipelines
4. A space where ventilation may be poor, • Is known to contain material with the • Containers
allowing gases to build up potential for engulfment
• The design of the space itself has the
potential to trap or asphyxiate the operator
entering the space
Gas hazards in confined spaces
Depending on the application, numerous

gases can be found in confined spaces.
The atmosphere may contain a mix of
flammable, toxic and Oxygen depletion gas
hazard risks. The typical gases that may be
encountered include but are not limited to:
• Oxygen
• Carbon Monoxide
• Hydrogen Sulphide GasAlertQuattro
GasAlertQua
attro GasAlertMax XT II GasAlertMicro 5
• Methane
• Ammonia
• Chlorine
• Nitrogen Dioxide
• Sulphur Dioxide
Due to the dangerous nature of confined

spaces, a two-step portable monitoring
procedure needs to be employed. The area
must first be tested and then continuous
monitoring of the space must take place for the
duration that the operator is working inside it.
Confined space stratified GasAlertMicroClip XT Impact Pro PHD6TM

testing (Step 1)
Before entering the confined space, a portable
gas detector combined with confined space Subsequent continuous - “Daisy chain” portable units together,
allowing one worker to be inside the
entry accessories such as manual aspirator kits monitoring (Step 2)
(if an integrated automatic sampling pump is confined space, whilst a second is
not available), and a sample hose with probe monitoring the entrant’s data from a safe
Even if no dangers are identified whilst
should be used. This will allow the operator to location on a second unit. This technique
performing the stratified testing, it is essential
be located outside of the confined space but is particularly useful in the most potentially
to monitor the confined space continuously
be able to draw air from inside it so it can be dangerous confined spaces
to ensure the atmosphere remains safe.
tested by the portable gas detector. Always remember that the atmosphere can
change quickly in a confined space. Monitoring confined space
It’s essential to sample the air at various levels applications
from floor to ceiling - heavier-than-air gases will - Use a 4-gas simultaneous portable
collect in low lying areas whilst lighter-than-air gas monitoring solution - 5 or 6 gas 4-gas portable devices like Impact Pro from
gases will collect at the highest levels. devices can be used for additional Honeywell Analytics and GasAlertQuattro
hazard coverage including and GasAlertMicroClip XT from
- Pay special attention to uneven floors or Photo Ionised Detection (PID) sensors BW Technologies by Honeywell can meet
ceilings that could allow high for the detection of low-level the needs of most confined spaces, but
concentrations of gas to form Volatile Organic Compounds (VOCs). additional protection (including VOC
- Always sample at a distance from the This makes solutions like GasAlertMicro 5 monitoring) can be delivered by a 5-gas
opening; air can intrude into the confined from BW Technologies by Honeywell and device such as GasAlertMicro 5 from
space resulting in false readings and PHD6TM from Honeywell flexible solutions BW Technologies by Honeywell or a 6-gas
inaccurate Oxygen level data for all confined space types device like PHD6TM from Honeywell.
- Once this full test has been conducted and - Choose a device with a robust crocodile
no hazards have been found, a worker can clip/harness so hands are free to
enter the confined space undertake the necessary work. Make sure
the portable gas detector is always
situated within the breathing zone (no
more than 25 cm/10 inches from the
mouth/nose)
61
GasAlertQuattro
Impact Pro
Marine
Marine gas hazards are numerous. Liquid gas, • Confined space entry including: Marine regulations:
fuel, chemicals and other fossil fuels harbor - Cargo compressor room
a risk of explosion and there is a danger of - Electric motor room
The marine industry is highly regulated
suffocation from Oxygen displacement when - Cargo-control room (unless classified
due to the potential hazards that can be
using Nitrogen or other gases for inerting. as gas-safe)
found, and legislation includes guidance on
- Enclosed spaces such as hold spaces
specific certifications that are required so
It is also important to be aware of dangers and inter-barrier spaces (with the
portable devices can be used within marine
presented by toxic gases such as exception of hold spaces containing
applications:
Carbon Monoxide from exhaust fumes, or Type ‘C’ cargo tanks)
Hydrogen Sulphide from the decomposition • Airlocks
• Within European Union (EU) Member
of organic compounds found in the briny • Burner platform vent hoods and engine
States portable gas detectors need to be
water inside ballast tanks. room gas supply pipelines
certified to the Marine Equipment Directive
• Hot work jobs
(MED)
Due to the mobility of ships, portable gas
• In some ports and countries across the
detection is used predominantly as it affords
Gas hazards in marine World it is recommended that portable
flexibility and mobility.
applications gas detectors are certified to the
American Bureau of Shipping (ABS)
Marine applications requiring • Flammables (various flammable fuels are
portable gas detection shipped via tanker including Monitoringmarineapplications
Liquid Petroleum Gas and Liquid Natural Gas)
Portable multi-gas monitoring solutions • Carbon Monoxide This makes devices like GasAlertQuattro
are an essential part of marine-based PPE, • Hydrogen Sulphide from BW Technologies by Honeywell and
providing operator protection in a variety of • Oxygen depletion (from inerting via Impact Pro from Honeywell Analytics, which
applications and environments: Nitrogen) both feature MED and ABS approval, ideal for
marine application monitoring.
• Protection whilst carrying out clearance
measurements of tanks and cargo bays
• Pre-entry check and subsequent
monitoring for confined spaces
• Inerting and purging
• Leak detection
Water treatment • Sewerage digester plant

- The process of decomposition is
Water treatment regulations:
accelerated in digesters, allowing There are a variety of standards (international
Water treatment is a large industry comprising filtered sludge to be converted into and national) governing the monitoring of
many processes and aspects from the a safe form for disposal. Depending on toxic, flammable and corrosive substances
production and distribution of clean water the origin of the waste, digesters will used in the water industry. For detailed
to the collection, treatment and disposal of promote either aerobic (in the presence information on the compliance requirements
waste such as sewage. of Oxygen) or anaerobic (without the for EU and Non-EU countries, please visit:
presence of Oxygen) decomposition. http://ec.europa.eu/environment/water/
Aside from the domestic provision and Both Methane and Carbon Dioxide water-framework/index_en.html and
treatment of clean water, industries such are by-products of these http://osha.europa.eu/en/good_practice/
as chemical manufacture, steel and food decomposition processes, creating the topics/dangerous_substances/oel/
processing may often have their own water need for portable gas detection when nomembers.stm/members.stm.
treatment plants. working near digesters.
Water treatment applications Monitoring water treatment

Gas hazards in water treatment applications
requiring portable gas applications
detection GasAlertQuattro, GasAlertMicroClip XT and
• Chlorine GasAlertMicro 5 from
• Purification plant monitoring • Sulphur Dioxide BW Technologies by Honeywell and
- Various chemicals including Chlorine, • Carbon Dioxide Impact Pro from Honeywell Analytics ideally
Sulphur Dioxide and Ammonia are • Ammonia Flammable gases meet the monitoring requirements of water
used to remove impurities from water. (Liquid Natural Gas and treatment applications.
It’s essential to use robust, multi-gas Liquid Petroleum Gas)
portable detectors during the • Nitrogen Dioxide
purification process and also when • Oxygen
entering or working in dosing rooms
where chemicals like Ammonia may be
used to “sweeten” the water.
Carbon Dioxide may also be present,
because it is used for PH correction to
lower water acidity.
• Power plant monitoring

- Water plants tend to feature their own
power generation for the purposes of
electricity generation and pumping.
This creates the need for fuels like
diesel and gas, creating the risk of
flammable gas hazards from the fuel GasAlertQuattro GasAlertMicro 5 GasAlertMicroClip XT
itself and also the exhaust fumes
(where Carbon Dioxide is a by-product
of combustion). A portable solution
with %LEL flammable gas
monitoring is essential in this
application.
• Waste water plant intake and penstocks

- As waste water enters the treatment
plant, penstocks (a form of gate)
halt/allow the flow of water into the
plant. Flammable risks may be Impact Pro
encountered because waste water
may contain Hydrocarbons from
spillages etc, so portable gas
detection is often used to perform
regular checks of water coming
into the plant.
63
Military • Pumping Hydrogen Sulphide is a real risk due to

• Storage tank filling the fact that the batteries that power
Most militaries – regardless of the country • Transportation submarines may produce Hydrogen.
they are located in – need to use gasoline, • Distribution Submarines may also feature flammable
gas oil or Kerosene to power their terrain • All works linked fuel management gases and other gases like
vehicles, ships, submarines, aircraft and • Confined space entry and inspection Volatile Organic Compounds (VOCs),
helicopters. Military fuel services contain • Aircraft tank inspection so it’s important to monitor for these too.
numerous applications that require portable • Submarine (please see below for more The septic tank onboard a submarine will
gas detection. detailed information) also pose a risk for Hydrogen Sulphide.
• Ship monitoring (please see bottom right
Militaries use dedicated fuel supply for more detailed information) Special considerations whilst undertaking
departments to manage and dispatch fuel to • Maintenance of engines and pumps submarine gas monitoring include the
all army operatives and in reality, the World’s avoidance of using Carbon Monoxide sensors
militaries are one of the biggest volume users In addition to the applications detailed above, because there can be cross-sensitivity issues
of these fuels. particular care and attention should be between Carbon Monoxide and
given to the following marine-based millitary Hydrogen Sulphide.
applications:
Military applications requiring
• Ship Monitoring: Hydrogen Sulphide
portable gas detection • Submarine monitoring: In a submarine is a risk near septic tanks and also where
the air is controlled by a dedicated there are confined spaces so its essential
• Storage tanks
analyser to ensure that the atmosphere to use a multi-gas portable when working
- Storage tank cleaning
is consistent and dangerous levels of in the vacinity of these locations.
- Storage tank inspections (in particular
Carbon Monoxide and Carbon Dioxide
ballasts where Hydrogen Sulphide and
are not allowed to build up. Carbon Monoxide poses a risk in engine
Carbon Monoxide may build up)
rooms, kitchens and can also be found in
GasAlertMicro 5
confined spaces. Ballasts can pose a Monitoring military fuels

danger of Oxygen depletion, as can
confined spaces. It’s important to Robust multi-gas solutions that offer
remember that Iron may be oxidised by sensitive detection combined with useability
Oxygen in ambient air, creating Iron Oxide are ideal for military fuel applications.
(also known as rust). This means that
Oxygen detection may also be required Historically, many military applications would
because the creation of rust can deplete specify 2, 3 or 4-gas portables (for the
Oxygen levels in the air creating deficiency detection of flammables, Oxygen depletion, PHD6TM
risks. Both VOCs and flammable gas risks Hydrogen Sulphide and Carbon Monoxide),
are likely in engine rooms, fuel storage to monitor for fuel supply-related gas risks.
locations and also where fuel is being In reality, a 5 or a 6-gas device is actually
used, replenished or re-located. preferable, as it delivers total coverage
against all gas hazards that can be found in
Gas hazards in military fuel supply applications.
applications
Devices like GasAlertMicro 5 PID, from
• Flammable gases (various blends of BW Technologies by Honeywell, provides a
Aviation Kerosene, Diesel and Gasoline) more comprehensive and effective monitoring
• Carbon Monoxide solution for military fuel supply, with the
• Carbon Dioxide ability to detect all toxic and exotic gas risks
• Hydrogen Sulphide that may be encountered. A military-specific
• Volatile Organic Compounds version of GasAlertMicro 5 PID is available
(including an automatic device test station
• Oxygen
and various additional accessories).
Bespoke carry case
65
Hazardous Material by HAZMAT responders. Response teams

can include various authorities, agencies and
Gas hazards in HAZMAT
applications
(HAZMAT)emergency groups including:
response • Fire departments

• Flammable gases including
Liquid Natural Gas, Liquid Petroleum Gas,
• Police
Accidents and releases involving Crude and Methane
• Spill response teams
Hazardous Materials (HAZMAT) can occur in a • Carbon Monoxide
• Air transport services
variety of locations including industry, on the • Carbon Dioxide
roads or at sea during the transportation of • Hydrogen Sulphide
materials.
HAZMATapplicationsrequiring • Sulphur Dioxide
portable gas detection • Chlorine
Depending on the nature of the release itself, • Nitric Oxide
various emergency response teams may It’s important to remember that incidents • Nitrogen Dioxide
be involved in the isolation and clean-up of involving HAZMAT can occur anywhere, but • Ammonia
hazardous materials, including fire brigades. the following examples are likely applications. • Phosphine
Many chemicals and compounds are • Chemical spillages on highways • Various Volatile Organic Compounds
classified as HAZMAT, due to their associated • Chemical spillages at sea • Oxygen
risk and potential detrimental effect to organic • Accidental releases at industrial plants
life and the environment. This makes quick, • Chemical releases into water ways Monitoring HAZMAT response
• Releases affecting commercial buildings
enhanced-safety HAZMAT response and applications
clean-up essential to minimise the impact or facilities
of dangerous solids, liquids and gases and • Pipeline infrastructure issues resulting
Emergency response teams may hold a stock
portable gas detection forms a key part of the in spills
of various devices that can be used during
Personal Protective Equipment (PPE) used specific incidents, owing to the large diversity
of HAZMAT classified materials. 4, 5 or 6-gas
portable detectors are ideal for emergency
response because of their flexibility. Devices
like GasAlertQuattro (4-gas portable),
GasAlertMicroClip XT (4-gas portable) and
GasAlertMicro 5 PID (5-gas portable) from
BW Technologies by Honeywell, Impact Pro
(4-gas portable) from Honeywell Analytics and
PHD6TM (6-gas) from Honeywell are all ideal
solutions for HAZMAT response purposes.
GasAlertQuattro GasAlertMicro 5
Oil and gas (offshore Oil and gas applications Gas hazards in oil and gas
requiring portable gas applications
and onshore) detection
• Flammable gases including
Safety-enhanced portable gas detection Liquid Natural Gas, Liquid Petroleum Gas,
A wide variety of applications require portable
forms an integral part of mandatory Crude and Methane
gas detection, but best practice guidance is
Personal Protective Equipment (PPE) required • Carbon Monoxide
that operators should always use a portable
for these challenging environments, owing • Hydrogen Sulphide
device to monitor for Hydrogen Sulphide.
to the abundance of potentially explosive • Carbon Dioxide
atmospheres that can build up during crude • Sulphur Dioxide
• Confined space testing and entry
extraction, transportation and subsequent • Ammonia
• Inerting of storage tanks
refinement. • Nitrogen Dioxide
• Crude extraction from the sea bed
• When working near storage tank farms • Oxygen
Floating Production Storage and Offloading
• Loading and offloading flammable
(FPSO) and refineries are classified as
“Top Tier” hazard installations and part of the
liquid/materials for transportation Monitoring oil and gas
risk reduction requirement includes the use of
• Working near refinery processes such as applications
Hydrocarbon cracking
portable gas detectors.
• During permit to work testing and when 4-gas portable detectors with IP 66/67
working in permit controlled areas like Impact Pro from Honeywell Analytics,
Offshore applications are often hard to reach
and accidents may require air rescue and air GasAlertQuattro and GasAlertMicroClip XT
emergency response, creating the need for from BW Technologies by Honeywell and
enhanced safety. Numerous flammable and MultiProTM from Honeywell provide the ideal
toxic gas hazards exist, including Oxygen monitoring solutions for these applications.
depletion risks from inerting with Nitrogen.
These locations may also be subject to The aforementioned examples represent some of the key applications for portable gas
severe adverse weather and sea spray, detection but if you are interested to learn about additional applications, please visit:
creating the need for the most robust solutions www.gasmonitors.com for application notes relating to portable products and
with enhanced Ingress Protection (IP). www.honeywellanalytics.com for application notes relating to fixed products.
67
PID Information
Measuring Solvent, vapours are heavier than air, and can act
to displace the atmosphere in an enclosed
it takes 5% volume Methane (50,000 PPM)
to achieve an ignitable concentration in air.
fuel and VOC vapours environment or confined space. Oxygen Because most VOCs produce flammable
in the workplace deficiency is a leading cause of injury and

death in confined space accidents. The
vapours, in the past, the tendency has been
to measure them by means of combustible
environment accident reports contain many examples gas measuring instruments. Combustible
of fatal accidents caused by Oxygen gas reading instruments usually provide
Solvent, fuel and many other deficiencies due to displacement by readings in percent LEL increments,
Volatile Organic Compound (VOCs) VOC vapours. where 100% LEL indicates a fully ignitable
vapours are pervasively common in many concentration of gas. Combustible gas
workplace environments. Most have Most VOC vapours are flammable at instrument alarms are usually set to go off if
surprisingly low occupational exposure surprisingly low concentrations. For the concentration exceeds 5% or 10% LEL.
limits. For most VOCs, long before you instance, the Lower Explosive Limit (LEL) Unfortunately, most VOC vapours are also
reach a concentration sufficient to register concentrations for Toluene and Hexane are toxic, with Occupational Exposure Limit
on a combustible gas indicator, you will only 1.1% (11,000 PPM). By comparison, (OEL) values much lower than the 5% or
have easily exceeded the toxic exposurere 10% LEL hazardous condition threshold for
limits for the contaminant. combustible gas. The toxic exposure limits
combu
exceeded long before the LEL alarm
are exc
A wide range of techniques and concentration is reached.
concen
equipment are available for measuring the
concentrations of these contaminants in n air. (OELs) are designed to protect workers
(OE
However, PID equipped instruments are e against the health effects of exposure
aga
generally the best choice for measurement
nt to hazardous substances. The OEL
of VOCs at exposure limit concentrations.. is the maximum concentration of an
Whatever type of instrument is used airborne contaminant to which an
to measure these hazards, it is unprotected worker may be exposed
essential that the equipment is used during the course of workplace
properly and the results are correctly activities. In the United Kingdom,
interpreted. OELs are listed in the EH40
Maximum Exposure Limits and
(VOCs) are organic compounds Occupational Exposure Standards.
characterised by their tendency EH40 currently lists exposure limits
to evaporate easily at room for about 500 substances. These
temperature. Familiar substances OELs are enforceable. Unprotected
containing VOCs include solvents, workers may not be exposed
paint thinner and nail polish remover, to a concentration of any listed
as well as the vapours associated substance that exceeds the limit.
with fuels such as gasoline, diesel, It’s up to the employer to determine
heating oil, kerosene and jet fuel. that these exposure limits are not
The category also includes many exceeded. In many cases, a direct
specific toxic substances such as reading gas detector is the primary
Benzene, Butadiene, Hexane, Toluene, means used to ensure that the OEL
Xylene, and many others. Increased has not been exceeded. OELs are
awareness of the toxicity of these generally defined in two ways, by
common contaminants has led to means of a Long Term Exposure
lowered exposure limits and increased Limit (LTEL) calculated as an 8-hour
requirements for direct measurement of Time Weighted Average (TWA)
these substances at their exposure limit and/or a Short Term Exposure Limit
concentrations. Photoionisation detector (STEL) that represents the maximum
equipped instruments are increasingly allowable concentration over a
being used as the detection technique of shorter period of time - usually a 10
choice in these applications. or 15 minute period. Exposure limits
for gases and vapours are usually
VOCs present multiple potential threats
s expressed in parts per million (PPM) or
e
in the workplace environment. Many VOCOC mg/m3 increments. The TWA concept
m
is based on a simple average of worker effects on exposed workers. Toxic motor movements. VOCs have also
exposure during an 8-hour day. The TWA substances tend to produce symptoms in two been implicated in kidney damage and
concept permits excursions above the TWA time frames: acute and chronic. immunological problems, including increased
limit only as long as they do not exceed the Hydrogen Sulphide (H2S) is a good cancer rates. Benzene, a notoriously toxic
STEL or ceiling and are compensated by example of an acutely toxic substance VOC found in gasoline, diesel, jet fuel and
equivalent excursions below the limit. For that is immediately lethal at relatively low other chemical products, has been linked
VOC vapours without a STEL, depending concentrations. Exposure to 1,000 PPM to chemically induced leukemia, aplastic
on the jurisdiction, the generally suggested produces rapid paralysis of the respiratory anaemia and multiple myeloma (a cancer
approach is to limit excursions above the system, cardiac arrest, and death within of the lymphatic system). There is good
TWA to a maximum of two to five times minutes. Carbon Monoxide (CO) also can act reason that the OEL’s for VOC vapours are
the 8-hour TWA OEL, averaged over a 10 rapidly at high concentrations (1,000 PPM) as low as they are. Unfortunately, because
to 15 minute period. Most direct reading although not as rapidly as Hydrogen Sulphide. of the chronic or long-term nature of the
instruments include at least three separate physiological effects of exposure, the
alarms for each type of toxic gas measured. While some VOCs are acutely toxic at tendency in the past has been to overlook
Typically, a toxic gas instrument will include low concentrations, most are chronically their potential presence in the workplace
an 8-hour TWA alarm, a STEL alarm and an toxic, with symptoms that may not environment at OEL concentrations.
instantaneous Ceiling alarm, (sometimes become fully manifested for years.
called the “Peak” alarm), that is activated
immediately whenever this concentration is
Exposure can be via skin or eye contact
with liquid or aerosol droplets, or via
Real-time
exceeded. Most gas detector manufacturers inhalation of VOC vapours. Inhalation can measurement
set their initial instantaneous “Peak” alarm
to the 8-hour TWA limit. This is a very
cause respiratory tract irritation (acute or
chronic) as well as effects on the nervous
techniques for
conservative approach. Although it is legally system such as dizziness, headaches and VOC vapours
permissible to spend an entire 8-hour day other long-term neurological symptoms.
at this concentration, most direct reading Long-term neurological symptoms can Commonly used techniques used to measure
VOC instruments are set to go into alarm the include diminished cognition, memory, VOC vapours include colorimetric detector
moment the instantaneous concentration reaction time, and hand-eye and foot-eye tubes, passive (diffusion) badge dosimeters,
exceeds the TWA limit. Instrument users, coordination, as well as balance and gait sorbent tube sampling systems, combustible
of course, are free to modify factory alarm disturbances. Exposure can also lead to gas monitors that use catalytic “Hot Bead”
settings to meet the demands of their mood disorders, with depression, irritability, combustible gas sensors to detect vapours in
specific monitoring programs. Airborne toxic and fatigue being common symptoms. percent LEL or PPM ranges, photoionisation
substances typically are classified on the Peripheral neurotoxicity effects include detectors (PIDs), flame ionisation detectors
basis of their ability to produce physiological tremors, and diminished fine and gross (FIDs) and infrared spectra-photometers.
69
All of these techniques are useful, or even for Hydrogen Sulphide, Carbon Monoxide, VOCs are quite detectable, but usually only
mandatory in specific monitoring applications. Chlorine, Sulphide Dioxide, Ammonia, by means of broad-range sensors.
However, the balance of this article will deal Phosphine, Hydrogen, Hydrogen Cyanide, Broad-range sensors provide an overall
with the most widely used types of portable Nitrogen Dioxide, Nitric Oxide, reading for a general class or group of
instruments used for VOC measurement in Chlorine Dioxide, Ethylene Dioxide, Ozone chemically related contaminants. They cannot
industrial safety applications: compact and others. distinguishbetweenthedifferentcontaminants
multi-sensor instruments equipped with they are able to detect. They provide a single
Oxygen, LEL combustible, electrochemical Although some of these sensors are aggregate reading for all of the detectable
toxic and miniaturised photoionisation cross-sensitive to other substances, there substances present at any moment.
detectors (PIDs). Portable gas detectors can is very little ambiguity when it comes
be equipped with a number of different types to interpreting readings. When you are The most widely used technique for the
of sensors. The type of sensor used is a interested in Hydrogen Sulphide, you use measurement of combustible gases and
function of the specific substance or class of a Hydrogen Sulphide sensor. When you VOCs continues to be the use of a
contaminant being measured. Many toxic are interested in Phosphine, you use a hot-bead pellistor type combustible gas
contaminants can be measured by means Phosphine sensor. In many cases, however, sensor. Pellistor sensors detect gas by
of substance-specific electrochemical a substance-specific sensor may not oxidising the gas on an active bead located
sensors. Direct reading sensors are available be available. within the sensor. Oxidisation of the gas
causes heating of the active bead. The
heating is proportional to the amount of gas
present in the atmosphere being monitored,
and is used as the basis for the instrument
reading. Most combustible gas reading
instruments display readings in % LEL
increments, with a full range of 0 - 100% LEL.
Typically these sensors are used to provide a
hazardous condition threshold alarm set to 5%
or 10% of the LEL concentration of the gases
or vapours being measured. Readings are
usually displayed in increments of + 1% LEL.
Hot-bead pellistor combustible gas sensors

are unable to differentiate between different
combustible gases. Hot-bead pellistor
sensors that display readings in + 1% LEL
increments are excellent for gases and
vapours that are primarily or only of interest
from the standpoint of their flammability.
Many combustible gases, such as Methane,
do not have a permissible exposure limit. For
these gases using a sensor that expresses
readings in percent LEL, increments is
an excellent approach. But many other
combustible vapours fall into a different
category. Although VOC vapours may be
measurable by means of a hot-bead sensor,
they may also have an OEL that requires
taking action at a much lower concentration.
Hexane provides a good example. Most

internationally recognised standards, such as
the Federal Republic of Germany Maximum
Concentration Value (MAK), the American
Conference of Governmental Hygienists
(ACGIH®) Threshold Limit Value (TLV®)
and the United States National Institute of
Occupational Safety and Health (NIOSH)
Recommended Exposure Limit (REL)
reference an 8-hour TWA for Hexane of
50 PPM. In the United Kingdom, the OEL for
Hexane is even more conservative. Although catalytic-bead sensors may molecule contains, the lower the IP. Thus, in
In the EU, the Long Term Exposure Limit have limitations with concern to the general, the larger the molecule, the easier it
(LTEL) for Hexane is a maximum of only measurement of toxic VOCs at exposure is to detect! This is exactly the opposite of the
20 PPM calculated as an 8-hour TWA. limit concentrations, they are by far the most performance characteristics of the catalytic
widely used and dependable method for hot-bead type combustible sensor.
The LEL concentration for Hexane is measuring Methane and other combustible
1.1%. Below 1.1% volume Hexane the gases and vapours with smaller, lighter Photoionisation detectors are easily able
concentration of Hexane vapour to air is too molecules. to provide readings at or below the OEL
low to form an ignitable mixture. Assuming or TLV® for all of the VOCs listed in
the combustible sensor alarm is set at Increasing concern with the toxicity of Table 1, including diesel. The best approach
10% LEL, with a properly calibrated VOCs has led to a number of newly revised to VOC measurement is often a multi-sensor
combustible gas reading instrument, it would exposure limits, including the TLVs® for instrument equipped with both LEL and
take a concentration of 10% of 1.1% = diesel vapour, kerosene and gasoline. PID sensors.
0.11% volume Hexane to trigger an alarm. Because the safety procedures for many
Since 1% volume = 10,000 parts-per-million
(PPM), every 1% LEL increment for Hexane
international corporations are tied to the most
conservative published standard, these new
Multi-sensor
is equivalent to 110 PPM. It would therefore TLVs® have been receiving a lot of attention detectors with PIDs
take a concentration of 1,100 PPM Hexane to around the World. The TLV® for diesel vapour
trigger an alarm set to the standard adopted in 2002 has proven to be particularly Catalytic hot-bead combustible sensors
10% LEL hazardous condition threshold. problematic, and has led to the revision of and photoionisation detectors represent
Even if instruments are set to alarm at numerous oil industry, maritime, and military complementary, not competing detection
5% LEL, it would require a concentration of health and safety monitoring programmes. techniques. Catalytic hot-bead sensors are
550 PPM to trigger the alarm. The ACGIH TLV® specifies an 8-hour TWA excellent for the measurement of Methane,
for total diesel Hydrocarbons (vapour and Propane, and other common combustible
Using a combustible gas monitor to measure aerosol) of 100 mg/m3. This is equivalent gases that are not detectable by means of
VOCs presents a number of other potential to approximately 15 parts-per-million a PID. On the other hand, PIDs can detect
problems. To begin with, most combustible diesel vapour. For diesel vapour, 1% LEL is large VOC and Hydrocarbon molecules that
sensors have poor sensitivity to the large equivalent to 60 PPM. Even if the instrument are effectively undetectable by hot-bead
molecules found in fuels, solvents and other is properly calibrated for the detection of sensors, even when they are operable in PPM
VOCs, with flashpoint temperatures higher diesel - which is not possible for many measurement ranges.
than 38ºC (100ºF). But even when the span designs - a reading of only 1% LEL would
sensitivity of a properly calibrated instrument exceed the TLV® for diesel by 600 percent! The best approach to VOC measurement
has been increased sufficiently to make up in many cases is to use a multi-sensor
for inherently lower sensitivity, an instrument It goes beyond the scope of this article to instrument capable of measuring all the
that provides readings incremented in argue how long it might be permissible to atmospheric hazards that may be potentially
1.0% LEL steps cannot resolve changes in remain at 5% or 10% LEL without actually present. Having a single instrument equipped
concentration smaller than ± 1.0% of the exceeding the 8-hour. TWA or STEL. What is with multiple sensors means no condition is
LEL concentration of the substance being most striking about the list is how few VOCs accidentally overlooked.
measured. Because percent LEL detectors have 8-hour TWA exposure limits higher than
are poor indicators for the presence of many 5% LEL. None of the VOCs on the list have
VOCs, lack of a reading is not necessarily exposure limits higher than 10% LEL.
proof of the absence of hazard.
Reliance on hot-bead type LEL sensors UsingPhotoionisation

for measurement of VOC vapours means
in many cases that the OEL, REL or TLV®
detectors to measure
is exceeded long before the concentration VOCs
of vapour is sufficient to trigger the
combustible hazardous condition threshold Photoionisation detectors use high-energy
alarm. When toxic VOCs are potentially ultraviolet light from a lamp housed within
present it is necessary to use additional or the detector as a source of energy used to
different detection techniques that are better remove an electron from neutrally charged
suited for direct measurement of VOCs at VOC molecules, producing a flow of electrical
PPM toxic exposure limit concentrations. current proportional to the concentration
Photoionisation detectors are becoming of contaminant. The amount of energy
increasingly popular for this application. needed to remove an electron from the target
molecule is called the Ionisation Potential (IP)
It should be noted that other combustible for that substance. The larger the molecule,
gases and vapours may be present at the or the more double or triple bonds the
same time as toxic VOCs.
71
Maintaining portable
gas detectors
Both field serviceable and disposable • Calibration: A calibration is usually “known poisons” are present, e.g. Silicone
portable gas detectors will require ongoing carried out twice yearly (although it may be poisoning catalytic bead flammable
maintenance and care throughout their undertaken more or less frequently in detection sensors. Depending on the
operational lives, although requirements are specific applications). This procedure type of device, sensors may be replaced
greatly reduced for disposable units. is designed to ensure that a portable gas individually or as part of an integrated
In general, there are three core activities that detector’s readings are truly representative cartridge (as used by devices like the
will need to be undertaken: of actual gas concentrations in the Impact range from Honeywell Analytics).
atmosphere. This is particularly important - This activity is applicable to field
• Functional device testing: This quick when dangerous gases like serviceable devices only
test (also known as bump testing) Hydrogen Sulphide may be present,
is carried out to ensure that a portable because just 1,000 PPM of this gas is • Datalogging: Although it is not considered
gas detector responds correctly, i.e. goes enough to kill in a single breath, therefore maintenance, datalogging is often
into alarm in the presence of a known incorrect readings could cause severe legislatively driven or imposed by
gas concentration. It is the only way injury or even death. insurance companies and involves the
of knowing a portable detector is working - This activity is applicable to field logging and documenting of portable gas
correctly and for this reason, best-practice serviceable devices only detector readings; especially when alarm
recommendation is to carry out a daily events occur.
bump test (please see How to perform • Sensor replacement: Sensors have a - This activity is applicable to both field
a bump test on page 73 for detailed defined expiry and must be replaced serviceable devices and disposable
information). after this period runs out. The average life portable gas detectors
- Bump testing is applicable to both field of sensors is approximately 2-3 years but
serviceable devices and disposable it is worth remembering that sensors may
portable gas detectors need to be replaced more frequently when
Reducing the cost of device

testing
When it comes to device bump testing and
datalogging, automatic test and datalogging
stations like those produced by Honeywell
can greatly reduce the cost and time
associated with ongoing device care. In fact, MicroDock II Enforcer IQ6 Docking Station
total labour and cost savings can be reduced
by as much as 40-60% (dependent on the
application and site-standards). A test and
datalogging solution from Honeywell can add
the following value:
• Minimise training by providing an intuitive,

single-button operation solution
• Reduce bump testing time by up to 80%
(when compared with a manual method)
• Controls all gas concentrations, preventing
too much gas being used, thus potentially
reducing test gas costs
• Datalogging with a single button press (no
need for PCs)
• No need for additional accessories such
as gas bottles, tubing, regulators etc
How to perform a manual BW Technologies by Honeywell’s range of a disposable product can have (with no
bump test portable gas detectors remind of aspects like need for calibration) over a field device. In
a “need to bump test or calibrate”, followed by reality, both are designed to the same high
If a test station is not desired, operators “forced bump testing” or “forced calibration”, standards, and the calibration of the field
can carry out bump testing manually in the which prevents the device from being device is not attributed to any difference in its
following way, using a portable unit and test used until the necessary activity has been constituent parts, but driven by compliance
kit accessories: performed. These aspects can be factory-set and mitigating the risk that the device
in order to meet specific site standards, i.e. may drift and not be representative of true
- Attach one end of the hose to the regulator no more than 180 days between calibrations. readings. With this in mind, many hazardous
of the gas cylinder and the other end to Such aspects can be further enhanced by applications are not legislatively allowed to
the bump test and calibration cap BW Technologies by Honeywell’s IntelliFlashTM use disposable units.
- Then attach the bump test and calibration technology (please see Value-added visual
cap to the device status indication on page 59 for detailed It is essential to take a holistic approach
- Apply a short 3 second blast of gas to information on IntelliFlashTM technology). when considering portable gas detection
the device and a suitable device will depend upon not
- The unit should go into alarm. If the device only specification and site needs but also
fails to alarm, it will need to be calibrated What drives device legislative requirements.
- Close the regulator and remove the maintenance?
calibration cap from the device. The unit
will continue to alarm until the gas clears It’s important to remember that portable
from the sensors devices are considered safety-critical and this
- The hose can then be disconnected from means that they are designed and maintained
the calibration cap and stored in a safe, in accordance with specific legislated
contaminant-free location directives and standards. With safety-critical
products and processes, risk potential is
Many devices today, including those built by mitigated wherever possible. There are
Honeywell, are optimised to deliver not only legislated requirements to check devices
user-friendly operation but fail-safe reminders (bump test) and calibrate them, depending
that ensure important maintenance needs on the application. This requirement
are undertaken when required. For example, explains the long period of operation that
73
Portable gas detection MultiProTM
from Honeywell
4-gas device with real-time simultaneous
Honeywell produces a wide variety of readings, simple one-button operation and
GasAlertMicroClip XT
portable devices designed to meet the a large easy-to-read LCD display. MultiProTM
application monitoring needs of diverse features an integrated black box data
industries; from low-cost, disposable recorder and event logger as standard. An
compliance units to functionality-rich, high optional screw-on pump with automatic leak
specification devices. The slim and compact GasAlertMicroClip XT test and low flow alarm is also available.
provides affordable protection from (Compatible with the Honeywell IQ Express
atmospheric hazards. With simple one-button Multi-Gas Docking Station).
GasAlertClipExtreme operation, this device offers ultimate ease
of use and significantly reduces time spent PHD6TM
training the user.
GasAlertMax XT II
Compact and affordable, GasAlertClipExtreme Simultaneous monitoring of up to 6-gas
offers 24/7 monitoring of single gas hazards hazards with 18 sensor choices, including PID
with zero maintenance requirements. With for the low-level detection of Carbon Dioxide
easy on/off operation, this single gas detector and Methane. PHD6TM features an integrated
is available in two and three year model The rugged GasAlertMax XT II monitors black box data recorder and event logger that
variants. up to four gas hazards and combines records all atmospheric hazards experienced
straightforward one-button field operation during operation. (Compatible with the
GasAlertExtreme with an integrated sampling pump. Honeywell IQ6 Multi-Gas Docking Station).
Tamper-proof, user-adjustable options enable
the instrument to be customised to suit Impact range
application needs.
Honeywell Analytics
Compact and affordable, GasAlertExtreme Experts in Gas Detection
GasAlertMicro 5 Series
reliably monitors for any single toxic gas
hazard. With easy on/off operation, this single High specification, 4-gas simultaneous
gas detector offers extended longevity with a monitoring solution designed to meet the
two year field-replaceable battery and sensor. needs of the most challenging applications.
Compact and lightweight, Model variants include Impact Pro, which
GasAlertQuattro GasAlertMicro 5 Series instruments are features an integrated automatic pump,
available in diffusion or pumped formats. Impact IR and Impact (standard).
These portable gas detectors simultaneously
monitor and display up to five atmospheric Impulse XT
hazards. Model variants include the
Rugged and reliable, the GasAlertQuattro Honeywell Analytics
GasAlertMicro 5 PID model for the low-level Experts in Gas Detection
4-gas detector combines a comprehensive
detection of VOCs and GasAlertMicro 5 IR for
range of features with simple one-button
Carbon Dioxide monitoring.
operation. The graphic LCD displays easy Impulse XT is a single-gas portable detection
to identify icons that indicate operational solution with zero maintenance requirements.
ToxiPro ®
information, such as bump test and calibration Delivering 24/7 monitoring with a two year
status for simplified on-site auditing. operational life, this device also features an
IP67 rating making it ideal for challenging
A compact and rugged single-gas toxic environments.
portable detector with one-button simplicity,
continuous real-time display and highly
visible/audible alarms for high noise locations.
ToxiPro® features an integrated black box
data recorder and event logger as standard
(compatible with the Honeywell
IQ Express Single Gas Docking Station).
Automatic device testing Enforcer Multi-Pro IQ Express

solutions from Honeywell Docking Station
Honeywell Analytics
MicroDock II Experts in Gas Detection
Designed for use with the Impact range of A fully automated bump test, calibration and
portable gas detectors, Enforcer is a small, datalogging station for use with the MultiProTM
lightweight test and calibration station that range of portable gas detectors. Connects to
The MicroDock II is an easy, cost-effective is fully portable. With no batteries or mains a PC via USB port or Ethernet (optional).
way to bump test, calibrate and charge a power required, Enforcer permits quick
device as well as manage records. Fully testing on the move and helps to reduce the IQ6 Docking Station
compatible with the complete ongoing cost of portable device maintenance.
BW Technologies by Honeywell product
range, its accompanying Fleet Manager II ToxiPro IQ Express
Docking Station A fully automated bump test, calibration and
software allows the user to download
datalogging station for use with the PHD6TM
information faster than ever from the
range of portable gas detectors. Connects to
MicroDock II. Improved functionality allows
a PC via USB port or Ethernet (optional).
the creation of accurate and user-friendly
A fully automated bump test, calibration and
reports, print receipts of calibration, sort and
datalogging station for use with the ToxiPro
graph data and archive information, helping
portable range, allowing four devices to be
to dramatically simplify fleet management
linked to a single gas supply. Connects to a
activities.
PC via USB port or Ethernet (optional).
75
16 North American
Hazardous Area
Standards and
Approvals
The North American
system for the
certification,
installation and
inspection of
hazardous locations
equipment includes
the following
elements:
• Installation Codes
– E.g. NEC, CEC
• Standard Developing Organisations (SDOs)
– E.g. UL, CSA, FM
• Nationally Recognised Testing Laboratories (NRTLs)
– Third Party Certifiers e.g. ARL, CSA, ETI, FM, ITSNA, MET, UL
• Inspection Authorities
– E.g. OSHA, IAEI, USCG
T
he installation codes used in The Nationally Recognised Testing
North America are the Laboratories (NRTLs) are independent
NEC 500 and NEC 505 and the third party certifiers who assess the
CEC (Canadian Electric Code) conformity of equipment with these
for Canada. In both countries these guides requirements. The equipment tested and
are accepted and used by most authorities as approved by these agencies is then suitable
the final standard on installation and use of for use under the NEC or CEC installation
electrical products. Details include equipment standards.
construction, performance and installation
requirements, and area classification In the United States of America the inspection
requirements. With the issuance of the new authority responsible is OSHA (Occupational
NEC these are now almost identical. Safety and Health Administration). In Canada
the inspection authority is the Standards
The Standards Developing Organisations Council of Canada. To confirm compliance to
(SDOs) work with industry to develop the all national standards both countries require
appropriate overall equipment requirements. an additional indication on products tested
Certain SDOs also serve as members of and approved.
the technical committees charged with the
development and maintenance of the As an example CSA approved product to
North American installation codes for USA standards must add NRTL/C to the CSA
hazardous locations. symbol. In Canada, UL must add a small c to
its label to indicate compliance to all
Canadian standards.
North American Ex Marking
and Area Classification
Once approved, the equipment must be marked to
indicate the details of the approval.
Class I – Explosive Gases

Division 1 Gases normally present in explosive amounts
Division 2 Gases not normally present in explosive amounts
Gas Types by Group

Group A Acetylene
Group B Hydrogen
Group C Ethylene and related products
Group D Propane and alcohol products
Class II – Explosive Dusts

Division 1 Dust normally present in explosive amounts
Division 2 Dust not normally present in explosive amounts
Dust Types by Group

Group E Metal dust
Group F Coal dust
Group G Grain and non-metallic dust
77
13 European
Hazardous Area
Standards and
Approvals
The standards used in most countries outside of North ICELAND
America are IEC/CENELEC and ATEX. The IEC (International

Electrotechnical Commission) has set detailed standards for
equipment and classification of areas and is the standard
that countries outside of both Europe and North America
use. CENELEC (European Committee for Electrotechnical
Standardisation) is a rationalising group that uses IEC
standards as a base and harmonises them with all ATEX
standards and the resulting standards legislated by member
countries, which are based upon ATEX. REPUBLIC OF
IRELAND
UNITED
T
he CENELEC mark is accepted
in all European Community (EC) KINGDOM NE
countries.
BE
All countries within the EC also have governing
bodies that set additional standards for
products and wiring methods. Each member
Key
country of the EC has either government or
third party laboratories that test and approve
Germany
products to IEC and/or CENELEC standards. CENELEC Members
Wiring methods change even under CENELEC,
this is primarily as to the use of cable, CENELEC Affiliate FRANCE
armoured cable, and type of armoured cable Water mass
or conduit. Standards can change within a
country “and referred as National Differences”
depending on the location or who built a
facility. Certified apparatus carries the
‘Ex’ mark.
ApprovedNational
Test Houses which
PORTUGAL
are cited in the EC SPAIN
Directivesmayuse
the EC Distinctive
Community Mark: Note: This is not a
Certification Mark
www.honeywellanalytics.com /www.gasmonitors.com
RUSSIA
CENELEC MEMBER COUNTRIES:

FINLAND
Austria Greece Poland
Belgium Hungary Portugal
Bulgaria Iceland Romania
NORWAY Croatia Ireland Slovakia
Cyprus Italy Slovenia
ESTONIA Czech Republic Latvia Spain
Denmark Lithuania Sweden
Estonia Luxembourg Switzerland
SWEDEN LATVIA
Finland Malta United Kingdom
France Netherlands
Germany Norway
LITHUANIA
DENMARK BALTIC SEA
BELARUS
POLAND
NETHERLANDS
UKRAINE
BELGIUM GERMANY
LUX CZECH REPUBLIC SEA OF

SLOVAKIA AZOV
any MOLDOVA
AUSTRIA
HUNGARY
E ROMANIA
SWITZ
SLOVENIA BLACK SEA
CROATIA
BOSNIA
SERBIA
BULGARIA
ITALY
MACEDONIA
TURKEY
ALBANIA
GREECE
CYPRUS
79
18 ATEX GAS
FACT
ATEX (an abbreviation of
ATmospheres EXplosibles)
sets the minimum safety
ATEX = ATmospheres EXplosibles standards for both the
Employer and Manufacturer
regarding explosive
atmospheres
There are two European Directives that
have been law since July 2003 that
detail the manufacturers and users
obligations regarding the design and use
of apparatus in hazardous atmospheres.
Responsibility Directive Article

Manufacturer 94/9/EC ATEX 95 ATEX 100a
End Users/Employers 99/92/EC ATEX 137
T
he ATEX directives set the In order to comply with the ATEX directive the
MINIMUM standards for both equipment must:
the employer and manufacturer • Display a CE mark
regarding explosive atmospheres. • Have the necessary hazardous area
It is the responsibility of the employer to certification
conduct an assessment of explosive risk and • Meet a recognised performance standard,
to take necessary measures to eliminate or e.g. EN 60079-29-1:2007 for flammable
reduce the risk. gas detectors (application specific)
ATEX DIRECTIVE 94/9/EC

ARTICLE 100A
Article 100a describes the manufacturer’s
responsibilities:
• The requirements of equipment and
protective systems intended for use in
potentially explosive atmospheres (e.g. Gas
Detectors)
• The requirements of safety and controlling
devices intended for use outside of
potentially explosive atmospheres but
required for the safe functioning of
equipment and protective systems (e.g.
Controllers)
• The Classification of Equipment Groups into
Categories
• The Essential Health and Safety
Requirements (EHSRs). Relating to
the design and construction of the
equipment/systems
The classification of hazardous areas is defined
in the ATEX directive
Hazardous area Definition ATEX
Zone 0 Areas in which explosive atmospheres Category 1
caused by mixtures of air and gases,
vapours, mists or dusts are present
continuously or for long periods of time
caused by mixtures of air and gases, vapours,
mists or dusts are likely to occur
caused by mixtures of air or gases, vapours,
mists or dusts are likely to occur or only occur
infrequently or for short periods of time
ATEX Category Permitted Certification Type

Category 1 Ex ia
Category 2 Ex ib, Ex d, Ex e, Ex p, Ex m, Ex o, Ex q
Category 3 Ex ib, Ex d, Ex e, Ex p, Ex m, Ex o, Ex q, Ex n
81
IEC Standards
IECEx (International Electrotechnical
Commission) provides standards that are ATEX Zones and IEC
widely used by countries outside of Europe
and North America. IECEx standards relate to
Equipment Groupings
area and equipment classification and provide
similar guidance to ATEX. ATEX Hazard Zone IEC Equipment code
Zone 0 (gas and vapours) 1G
Zone 20 (combustible dusts) 1D
IEC Equipment Categories and Method of

Protection for Gas and Vapour Hazards
Equipment category Type of protection Code IECEx reference
1G Intrinsically Safe ia EN/IEC 60079-11
1G Encapsulation ma EN/IEC 60079-18
2G Flameproof enclosure d EN/IEC 60079-1
2G Increased safety E EN/IEC 60079-7
2G Intrinsically Safe ib EN/IEC 60079-11
2G Encapsulation m / mb EN/IEC 60079-18
2G Oil immersion o EN/IEC 60079-6
2G Pressurised enclosures p / px / py EN/IEC 60079-2
2G Powder filling q EN/IEC 60079-5
3G Intrinsically Safe ic EN/IEC 60079-11
3G Encapsulation mc EN/IEC 60079-18
3G Non-sparking n / nA EN/IEC 60079-15
3G Restricted breathing nR EN/IEC 60079-15
3G Energy limitation nL EN/IEC 60079-15
3G Sparking equipment nC EN/IEC 60079-15
3G Pressurised enclosures pz EN/IEC 60079-2
IEC Equipment Categories and Method of
Protection for Combustible Dust Hazards
Equipment category Type of protection Code IECEx reference
1D Intrinsically Safe ia EN/IEC 60079-11
1D Encapsulation ma EN/IEC 60079-18
1D Enclosure ta EN/IEC 61241-1
2D Intrinsically Safe ib EN/IEC 60079-11
2D Encapsulation mb EN/IEC 60079-18
2D Enclosure tb EN/IEC 61241-1
2D Pressurised enclosures pD EN/IEC 61241-2
3D Intrinsically Safe ic EN/IEC 60079-11
3D Encapsulation mc EN/IEC 60079-18
3D Enclosure Tc EN/IEC 61241-1
3D Pressurised enclosures pD EN/IEC 61241-2
83
Equipment Markings
ATEX DIRECTIVE 99/92/EC
Assessment of
For further information about this directive,
ARTICLE 137 please visit: http://ec.europa.eu/enterprise/
ATEX 99/92/EC Article 137 describes the
responsibilities of the employer/end user
policies/european-standards/documents/
harmonised-standards-legislation/ Explosion Risks
regarding the use of equipment designed for list-references/equipment-explosive-
The employer must conduct
use in potentially explosive atmospheres. atmosphere/index_en.htm. Member States
Unlike other directives, which are advisory use this information to draw up their own
a risk assessment including:
in nature, ATEX is part of the New Approach legislation. For example, in the UK, this
Directives issued by the European Union (EU)
and is mandatory.
legislation is implemented by the Health and
Safety Executive (HSE) as the Dangerous
Substances and Explosive Atmospheres
1 PROBABILITY
OF EXPLOSIVE
ATMOSPHERE
Regulations 2002 (DSEAR). Zone Area classification
It sets out to:
if not
2 PROBABILITY OF
IGNITION SOURCE
Prevent Avoid
the ignition
Equipment Categories
the formation
3
of explosive of explosive NATURE OF
atmospheres atmospheres
FLAMMABLE
MATERIALS
Gas groups, ignition temperature
(T rating), gas, vapour, mists and
dusts
if not
Control SCALE OF EFFECT
the effects of
explosions 4 OF EXPLOSION
Equipment Protection Level
60079 Series
Ex d IIC T5 (Tamb -40˚C to +55˚C)
Apparatus Referenced to
group ambient –20˚C
to +40˚C unless
Type of indicated as above
protection
Equipment
EU explosion protection level
protected Temperature Class (Group II)
(Ex) symbol
Explosive Atmospheres
Warning Sign
The employer must mark points of entry to In carrying out the assessment of explosion
places where explosive atmospheres may risk the employer shall draw up an Explosion
occur with distinctive signs: Protection Document that demonstrates:
• explosion risks have been determined

and assessed
• measures will be taken to attain the aims
of the directive
• those places that have been classified
into zones
• those places where the minimum
requirements will apply
• that workplace and equipment are
designed, operated and maintained with
due regard for safety
The employer may combine existing
Ex
explosion risk assessments, documents or
equivalent reports produced under other
community acts. This document must be
revised with significant changes, extensions
or conversions.
ATEX Markings
0999 II 2 G Type of explosive atmosphere
G : Gas, mist, vapour
D : Dust
Equipment category
Gas Dust Mining
1 : Zone 0 1 : Zone 20 M1 : Energised
CE Mark Notified body 2 : Zone 1 2 : Zone 21 M2 : De-energised
number 3 : Zone 2 3 : Zone 22
Equipment group
I : Mining
II : Other areas (Ex)
EU Explosive atmosphere symbol
85
19 Area
Classification
N
ot all areas of an
industrial plant or site are
considered to be equally
hazardous. For instance, an
underground coal mine is considered at
all times to be an area of maximum risk,
because some Methane gas can always
be present. On the other hand, a factory
where Methane is occasionally kept
on site in storage tanks, would only be
considered potentially hazardous in
the area surrounding the tanks or any
connecting pipework. In this case, it is
only necessary to take precautions in
those areas where a gas leakage could
reasonably be expected to occur.
In order to bring some regulatory

control into the industry, therefore,
certain areas (or ‘zones’) have been
classified according to their perceived
likelihood of hazard. The three zones
are classified as:
ZONE 0 ZONE 1 ZONE 2

In which an explosive gas/air mixture is In which an explosive gas/air mixture is In which an explosive gas/air mixture is
continuously present, or present for likely to occur in the normal operation of not likely to occur in normal operation
long periods the plant
Continuous Hazard Intermittent Hazard Possible Hazard

Europe/IEC Zone 0 Zone 1 Zone 2
North America (NEC 505) Zone 0 Zone 1 Zone 2
North America (NEC 500) Division 1 Division 2
In North America the classification most often used (NEC 500) includes
only two classes, known as ‘divisions’.
Division 1 is equivalent to the two European Zones 0 and 1 combined,
whilst Division 2 is approximately equivalent to Zone 2.
Area Classification Example
ZONE 2
PETROLEUM
ZONE 1
ZONE 0
ZONE 1
ZONE 0
87
20 Apparatus
Design
To ensure the safe operation of electrical equipment in flammable atmospheres,
several design standards have now been introduced. These design standards
have to be followed by the manufacturer of apparatus sold for use in a
hazardous area and must be certified as meeting the standard appropriate to
its use. Equally, the user is responsible for ensuring that only correctly designed
equipment is used in the hazardous area.
F
or gas detection equipment, the Intrinsically safe apparatus is designed so that or exceed the limiting temperature in
two most widely used classes the maximum internal energy of the apparatus normal service.
of electrical safety design are and interconnecting wiring is kept below that
‘flameproof’ (sometimes known as which would be required to cause ignition A further standard, Encapsulation
‘explosion-proof’ and with an identification by sparking or heating effects if there was (Ex m) is a means of achieving safety by
symbol Ex d) and ‘intrinsically safe’ with the an internal fault or a fault in any connected the encapsulation of various components
symbol Ex ia or Ex ib. equipment. There are two types of intrinsic or complete circuits. Some products now
safety protection. The highest is Ex ia which is available, achieve safety certification by virtue
Flameproof apparatus is designed so that its suitable for use in Zone 0, 1 and 2 areas, and of using a combination of safety designs
enclosure is sufficiently rugged to withstand Ex ib which is suitable for use in Zone 1 and 2 for discrete parts. Eg. Ex e for terminal
an internal explosion of flammable gas without areas. Flameproof apparatus can only be used chambers, Ex i for circuit housings, Ex m
suffering damage. This could possibly result in Zone 1 or 2 areas. for encapsulated electronic components
from the accidental ignition of an explosive and Ex d for chambers that could contain a
fuel/air mixture inside the equipment. The Increased safety (Ex e) is a method of hazardous gas.
dimensions of any gaps in the flameproof case protection in which additional procedures
or box (e.g. a flange joint) must therefore be are applied to give extra security to electrical
calculated so that a flame can not propagate apparatus. It is suitable for equipment in
through to the outside atmosphere. which no parts can produce sparking or arcs
Flameproof Intrinsically Safe

Only cooled gas
can escape Flamep path R L
Explosion contained
in Ex d enclosure
Hazardous Area Design Standards
Division Zone Ex Type of protection
0 Ex ia intrinsically safe
Any design suitable for zone 0 plus:
Ex d flameproof
Ex ib intrinsically safe
1
Ex p pressurised/continuous dilution
1
Ex e increased safety
Ex s special
Ex m encapsulation
Any design suitable for zone 1 plus:
Ex n or N non-sparking (non-incendive)
2 Ex o oil
2
Ex q powder/sand filled
Increased Safety
Gasket
89
21 Apparatus
Classification
As an aid to the selection of apparatus for safe use in different
environmental conditions, two designations, apparatus group and
temperature classification, are now widely used to define their limitations.
A
s defined by standard No GROUP II Acetylene is often considered to be so
EN60079-20-1 of the European For places with a potentially explosive unstable that it is listed separately, although
Committee for Electrical atmosphere, other than Group I mines. still included in Group II gases. A more
Standards (i.e. Committee comprehensive listing of gases can be found
European de Normalisation Electrotechnique Group II clearly covers a wide range of in European Standard EN 60079-20-1.
or CENELEC), equipment for use in potentially potentially explosive atmospheres and
explosive atmospheres is divided into two includes many gases or vapours that The Temperature Class rating for safety
apparatus groups: constitute widely different degrees of hazard. equipment is also very important in the
Therefore, in order to separate more clearly the selection of devices to detect gas or mixture
GROUP I differing design features required when used in of gases. (In a mixture of gases, it is always
For mines which are susceptible to firedamp a particular gas or vapour, Group II gases are advisable to take the ‘worst case’ of any
(Methane). sub-divided as indicated in the table. of the gases in the mixture). Temperature
classification relates to the maximum surface
temperature which can be allowed for a piece
of apparatus. This is to ensure that it does not
exceed the ignition temperature of the gases
or vapours with which it comes into contact.
The range varies from T1 (450°C) down to

T6 (85°C). Certified apparatus is tested in
accordance with the specified gases or
vapours in which it can be used.
Both the apparatus group and the temperature
classification are then indicated on the safety
certificate and on the apparatus itself.
North America and the IEC are consistent in

their temperature or T-Codes. However unlike
the IEC, North America includes incremental
values as shown opposite.
Apparatus Group
Representative Gas Gas Classification Ignitability
Europe and IEC countries US and Canada
Acetylene Group IIC Class I, Group A
Hydrogen Group IIC Class I, Group B
Easier to ignite
Ethylene Group IIB Class I, Group C

Propane Group IIA Class I, Group D
Methane Group I No classification
Temperature
Class
T1=450 T1=450
T2=300 T2=300
T2A=280
T2B=260
T2C=230
T2D=215
T3=200 T3=200
T3A=180
T3B=165
T3C=160
T4=135 T4=135
T4C=120
T5=100 T5=100
T6=85 T6=85
o
C
91
22 Ingress Protection
of Enclosures
Coded classifications are now widely used to indicate the degree of
protection given by an enclosure against entry of liquids and solid materials.
This classification also covers the protection of persons against contact
with any live or moving parts inside the enclosure. It should be remembered
that this is supplementary to and not an alternative to the protection
classifications for electrical equipment used in hazardous areas.
I
n Europe the designation used
to indicate the Ingress Protection
consists of the letters IP followed by
two ‘Characteristic Numbers’ which
indicate the degree of protection. The first
number indicates the degree of protection
for persons against contact with live or
moving parts inside, and the second number
shows the enclosure’s protection against
entry of water. For example, an enclosure
with a rating of IP65 would give complete
protection against touching live or moving
parts, no ingress of dust, and would be
protected against entry from water spray or
jet. This would be suitable for use with gas
detection equipment such as controllers, but
care should be taken to ensure adequate
cooling of the electronics. There is also a
third numeral sometimes used in certain
countries, relating to impact resistance.
The meanings of the numbers are given in
the following table.
Third Numeral Meaning

0 No Protection
1 Impact of 0.225 Joule (150g weight dropped from 15cm)
4 (No meaning)
6 (No meaning)
7 Impact of 6.0 Joule (1.5Kg weight dropped from 40cm)
8 (No meaning)
9 Impact of 6.0 Joule (5Kg weight dropped from 40cm)
IP codes (IEC / EN 60529)
First Numeral Second Numeral
Protection against solid bodies IP Protection against liquid
No protection 0 0 No protection
Objects greater than 50mm 1 1 Vertically dripping water
Objects greater than 12mm 2 2 Angled dripping water -75º to 90º
Objects greater than 2.5mm 3 3 Splashed water
Objects greater than 1.0mm 4 4 Sprayed water
Dust protected 5 5 Water jets
Dust tight 6 6 Heavy seas
7 Effects of immersion (defined in minutes)
8 Indefinite immersion
Example: IP67 is dust tight and protected against the effects of immersion
NEMA ratings with IP ratings

In North America enclosures are rated using the NEMA system. The table below
provides an approximate comparison of NEMA ratings with IP ratings.
NEMA, UL and CSA Approximate

type rating IEC/IP Code Description
1 IP20 Indoor, from contact with contents
2 IP22 Indoor, limited, falling dirt and water
3 IP55 Outdoor from rain, sleet, windblown dust

and ice damage
3R IP24 Outdoor from rain, sleet and ice damage
Indoor and outdoor, from windblown dust,
4 IP66 splashing and hose directed water and ice
damage
Indoor and outdoor, from corrosion,
4X IP66 windblown dust, rain, splashing and hose
directed water and ice damage
Indoor and outdoor, from hose directed
6 IP67 water, water entry during submersion and
ice damage
12 IP54 Indoor, from dust, falling dirt and dripping

non corrosive liquids
13 IP54 Indoor, from dust, falling dirt and dripping

non corrosive liquids
93
23 Safety Integrity
Levels (SIL)
Certification has essentially been concerned with the safety of a product in its working
environment i.e. that it won’t create a hazard in its own right. The certification process
(particularly in Europe with the introduction of the ATEX standard pertaining to Safety
Related Devices) has now moved on to also include the measurement/physical
performance of the product. SIL adds a further dimension by being concerned
with the safety of the product in terms of being able to carry out its
safety function when called to do so (Ref: IEC 61508 manufacturers
requirement). This is increasingly being demanded as installation
designers and operators are required to design and document
their Safety Instrumented Systems (Ref: IEC 61511 user’s requirement).
I
ndividual standards applicable to its safety function goes undetected. There is
specific types of equipment are being a critical distinction between reliability and
developed from IEC61508. For gas safety. A product which appears to be reliable
detection equipment the relevant may have unrevealed failure modes whereas a
standard is EN50402:2005+A1:2008 Electrical piece of equipment which appears to declare
apparatus for the detection and measurement a large number of faults may be safer as it is
of combustible or toxic gases or vapours or never/rarely in a condition where it is unable
of Oxygen. Requirements on the functional to do its function or has failed to annunciate
safety of fixed gas detection systems. its inability to do so.
Managing safety is about risk reduction.

All processes have a risk factor. The aim is to
reduce the risk to 0%. Realistically, this is not
possible so an acceptable risk level that is
‘As Low As Reasonably Practical’ (ALARP) is
set. Safe plant design and specification is the
major risk reduction factor. Safe operational
procedures further reduce the risk as does a
comprehensive maintenance regime.
TheE/E/PES(Electrical/Electronic/Programmable
Electronic System) is the last line of defence
in the prevention of accidents. SIL is a
quantifiable measure of safety capability of the
E/E/PES. In typical applications, this relates
to the F&G systems-detectors, logic resolvers
and safety actuation/annunciation.
It is recognised that all equipment has failure

modes. The key aspect is to be able to
detect when the failures have occurred and
take appropriate action. In some systems,
redundancy can be applied to retain a
function. In others, self checking can be
employed to the same effect. The major
design aim is to avoid a situation where a
fault which prevents the system carrying out
There are 4 levels of SIL and the higher the SIL, the lower its resulting
Probability of Failure on Demand (PFD). Many current fire and gas
detection products were designed before the introduction of SIL and
therefore on individual assessment may only achieve a low or non-SIL
rated status. This problem can be overcome by techniques such as
decreasing the proof test intervals or combining systems with different
technologies (and hence eliminating common mode failures) to increase
the effective SIL rating.
100% For a safety system to achieve a specified SIL, the sum of the PFD must
be considered.
Plant design
SIL Probability of failure on demand
1 > 10–2 to < 10–1
> 10–3 to < 10–2
equipment
2
Safer
3 > 10–4 to < 10–3

4 > 10–5 to < 10–4
Operation
RISK
Sensor Logic Resolver Safety Actuation
GAS DETECTOR MEASUREMENT SHUT OFF VALVE

Maintenance RESOLVER, ALARM
LEVEL, VOTING
For SIL 2 PDF (Sensor) + PFD (Resolver) + PDF (Actuator) < 1x10-2
E/E/PES The selection of SIL required for the installation must be made in
conjunction with the level of safety management within the design of the
Fire and Gas system
0%
process itself. The E/E/PES should not be considered the primary safety
system. Design, operation and maintenance have the most significant
ALARP combination to the safety of any industrial process.
95
24 Gas Detection
Systems
The most common method employed to continuously monitor for
leakage of hazardous gases is to place a number of sensors at the
places where any leaks are most likely to occur. These are often
then connected electrically to a multi-channel controller located
some distance away in a safe, gas free area with display and alarm
facilities, event recording devices etc. This is often referred to as a
fixed point system. As its name implies, it is permanently located in
the area (e.g. an offshore platform, oil refinery, laboratory
cold storage etc).
T
he complexity of any gas detection
system depends on the use to
which the data will be put.
Data recording allows the
information to be used to identify problem
areas and assist in the implementation of
safety measures. If the system is to be used
for warnings only, then the outputs from the
system can be simple and no data storage is
necessary. In choosing a system, therefore, it is
important to know how the information will be
used so that the proper system components
can be chosen. In toxic gas monitoring,
the use of multi-point systems has rapidly
demonstrated their potential for solving a wide
variety of workplace exposure problems and is
invaluable for both identifying problems and for
keeping workers and management aware
of pollutant concentrations in the workplace.
In the design of multi-point systems,

considerable thought should be given to the
variouscomponentsandtotheirinterconnection.
When using catalytic detection sensors, for
instance, the electrical cable connections to
the sensors would have three cores, each of
1mm squared, carrying not only the output
signal, but also power to the electrical bridge
circuit, which is located at the sensor to
reduce signal voltage drop along the cables.
In the case of toxic (and some flammable)

gas monitoring systems, the atmosphere is
often sampled at locations remote from the
unit and the gases are drawn by pumps to
the sensors through a number of synthetic
material, narrow-bore tubes. Care in design
of such systems will include a selection of
Typical small gas detection system protecting a room
Key 20m
GD Gas Detector V A R
V A GD
V A Audible and Visual Alarm
R Remote Reset
GD GD
F Fused Spur
GD
Control Panel F V A
suitable sized pumps and tubes, a sequential remember that the main purpose of a gas to ensure that all the gland sizes and screw
sampling unit for sampling each tube in turn detection system is to detect the build up threads are compatible with the junction box
and filters to stop particles or water cutting off of a gas concentration before it reaches a and the external diameter of the cables being
the flow of gas. The bore size of tubing can be hazardous level and to initiate a mitigation used. The correct sealing washer should be
critical, since it needs to be both large enough process to prevent a hazard occurring. used to ensure a weatherproof seal between
to allow rapid response times with standard If the gas concentration continues towards a the detector and junction box. A further point
size pumps, but at the same time should not hazardous level then executive shut down and to remember is that sensor manufacturers
be so large as to allow excessive dilution of hazard warning alarms are initiated. It is not normally indicate the maximum loop resistance
the sample by air. Each sampling point must enough to just log the event or measure (not line resistance) of their sensor connections
be connected to a separate tube and if a the gas levels to which personnel have when providing the information to calculate
number of points are connected to a single, been exposed. cable core diameters for installation.
central sensor, it will be necessary to purge
the sensor with clean air between samples. CABLES AND JUNCTION BOXES
The controllers used in fixed systems In a typical industrial gas detection system
can be centrally located or distributed at such as that just described, sensors are
various locations in a facility according to located at a number of strategic points
the application requirements. They come around the plant and at varying distances
in a control panel and come in either single from the controller. When installing electrical
channel (i.e. one control card per sensor) or connections to the controller, it is important to
multi-channel configurations, the latter being remember that each sensor cable will have a
useful where power, space or cost limitations different electrical loop resistance depending
are important. upon its length. With constant voltage type
detectors, the calibration process will require
The control units include a front panel meter a person at both the sensor in the field and at
or LCD to indicate the gas concentration the controller. With constant current detectors
at each sensor and will also normally have or those with a local transmitter, calibration of
internal relays to control functions such the field device can be carried out separately
as alarm, fault and shutdown. The number to that of the controller.
of alarm levels available varies between
controllers but typically up to three levels can The sensor cables are protected from external
be set, depending on statutory requirements damage either by passing them through metal
or working practices within the industry. ducting, or by using a suitable mechanically
Other useful features would include alarm protected cable. Protective glands have
inhibit and reset, over-range indication and to be fitted at each end of the cable and
analogue 4-20mA outputs. Often digital the sensor is mounted on a junction box
outputs are also available for interfacing the to help in making simple, low-resistance,
controller to a DCS/BMS. It is important to ‘clean’ terminations. It is also very important
97
Location of Sensors GAS
‘How many detectors do I need?’ and ‘where should I locate
them?’ are two of the most often asked questions about gas FACT
Xenon is the rarest
detection systems, and probably two of the most difficult non-radioactive gas
element in the Earth’s
to answer. Unlike other types of safety related detectors, such atmosphere. It represents
as smoke detectors, the location and quantity of detectors 90 parts-per-billion of the
total atmosphere
required in different applications is not clearly defined.
C
onsiderable guidance is available These references are useful, but tend to be Detectors should be mounted where the gas is
from standards such as either very generic and therefore too general most likely to be present. Locations requiring
EN 60079-29-2 and others in detail, or application specific and therefore the most protection in an industrial plant
regarding the selection, irrelevant in most applications. would be around gas boilers, compressors,
installation, use and maintenance of pressurised storage tanks, cylinders or
apparatus for the detection and measurement The placement of detectors should be pipelines. Areas where leaks are most likely
of combustible gases or Oxygen. Similar determined following the advice of experts to occur are valves, gauges, flanges, T-joints,
international codes of practice e.g. National having specialist knowledge of gas dispersion, filling or draining connections etc.
Electrical Code (NEC) or Canadian Electrical combined with the knowledge of
Code (CEC) may be used where applicable. process/equipment engineers and safety There are a number of simple and quite often
In addition, certain regulatory bodies publish personnel. The agreement reached on the obvious considerations that help to determine
specifications giving minimum gas detection location of detectors should also be recorded. detector location:
requirements for specific applications.
Perhaps the most important point of all is not to try and economise by
! using the minimum number of sensors possible. A few extra sensors could
make all the difference if a gas leak occurs!
• To detect gases that are lighter than air clouds to form. Otherwise any leak of gas is
(e.g. Methane and Ammonia), detectors likely to pass by in a high speed jet and not
should be mounted at high level and be detected
preferably use a collecting cone • Consider ease of access for functional
• To detect heavier than air gases testing and servicing
(e.g. Butane and Sulphur Dioxide), detectors • Detectors should be installed at the
should be mounted at a low level designated location with the detector
• Consider how escaping gas may behave pointing downwards. This ensures that
due to natural or forced air currents. Mount dust or water will not collect on the front of
detectors in ventilation ducts if appropriate the sensor and stop the gas entering the
• When locating detectors consider the detector
possible damage caused by natural events • When installing open path infrared devices
e.g. rain or flooding. For detectors mounted it is important to ensure that there is no
outdoors it is preferable to use the weather permanent obscuration or blocking of
protection assembly the IR beam. Short-term blockage from
• Use a detector sunshade if locating a vehicles, site personnel, birds etc can be
detector in a hot climate and in direct sun accommodated
• Consider the process conditions. Butane • Ensure the structures that open path
and Ammonia, for instance are normally devices are mounted to are sturdy and not
heavier than air, but if released from susceptible to vibration
a process line that is at an elevated
temperature and/or under pressure, the gas
may rise rather than fall
• Detectors should be positioned a little way
back from high pressure parts to allow gas
99
Typical Sensor Mounting Options
GAS
1. Wall mounted
2. Pole mounted
3. Ceiling mounted
4. Duct mounted FACT
Jupiter – our solar system’s
largest gas giant – contains
about 90% Hydrogen and 10%
Typical System Configurations Helium. In fact, its composition
is actually very similar to a
primordial Solar Nebula (the
5. Remote sensor, local display/gassing type of Nebular that our solar
system developed from).
6. Locally driven alarm system
7. Typical sensor/controller system
8. Standalone system
9. Typical sampling/aspirating system
1 2
Metal clamps
Junction box/
transmitter
Bolts
According to
EN 60079-29-1 the
minimum distance
Sensor
here is 50mm
According to
EN 60079-29-1 the
Pole minimum distance
here is 50mm
3 4
Screws/bolts Junction box/ Gassing

transmitter point
Weather
Junction box/ protection
transmitter assembly with Gas
gassing nozzle tubing
Sounting duct
plate Sensor
5 6
Remote
sensor
Locally driven
Remote audible/visual alarm Optional audible/
Weather sensor visual alarm
protection with cable
gassing nozzle
Gas
tubing
Gassing point Local relays Controller

assembly in transmitter PLC/DCS
Local
display
7 8
Indoors Outdoors
Local Audible/visual
relays alarm
Controller in transmitter
PLC/DCS
According to
Hazardous area Control system EN 60079-29-1 the
in the field in safe area minimum distance
here is 50mm
control room
9
Audible/visual
alarm
Intrinsically
safe system
Calibration
Sample in
DA N G E R
2 4 0VO L
TS
Exhaust
Pump
101
25 Installation
Cross section of
typical SWA cable
Essentially three installation methods
are used Worldwide for electrical
equipment in hazardous locations:
1. Cable with indirect entry This cable gland is the only type that can meet the
IEC 60079-14 requirements. It prevents the migration of
2. Cable with direct entry gas between the conductors and it features an extruded
3. Conduit inner cable bedding.
Cable Systems
These are mainly used in Europe (although the US and
Canadian Electrical Codes list Metal Clad and Mineral
Insulated cables for use in Class 1 Div 1 or Zone 1).
Ex standards state that cable systems with suitable
mechanical protection must be used. The cable is often
Steel Wire Armoured (SWA) if used in areas where
mechanical damage may occur, or it may be laid in
protective conduit which is open at both ends.
Certified cable glands are used to safely connect the
cable to the enclosure. Cutaway of typical cable gland
Indirect Cable Entry

These are mainly used in Europe (although the US and Canadian
Electrical Codes list Metal Clad and Mineral Insulated cables for
use in Class 1 Div 1 or Zone 1). Explosion-proof standards state
that cable systems with suitable mechanical protection must be
used. The cable is often Steel Wire Armoured (SWA) if used in areas
where mechanical damage may occur, or it may be laid in protective
conduit which is open at both ends. Certified cable glands are used
to safely connect the cable to the enclosure.
Ex e Terminal Area
Ex e Cable Gland
Flameproof enclosure
Direct Cable Entry
A2FFC (Indoor/outdoor use, Ex d, Ex ia) D3CDS (for use with marine, ordinary
and hazardous area cables)
E1FU (Deluge protected, flameproof, Ex d, Ex ia) PX2KX (for use with armoured and jacketed cables)
Deluge proof option
C2K (Amoured cable, Ex) TC (for use in wet/deluge, hazardous locations)
Direct Cable Entry Conduit

Direct Cable Entry is made into the flameproof enclosure. Conduit is the main method of installation in hazardous
Only specially certified glands may be used. The type areas throughout the USA. The electrical wires are run
and structure of the cable must be carefully matched to as individual wires inside enclosed metal tubes.
the correct type of gland. The integrity of the protection The tubes are connected to the housings by means of
is reliant on the correct installation by the installer. unions and must have a seal within 18 inches (457.2mm)
of each entrance point. The entire conduit system
is flameproof.
Ex d Cable Gland
Flameproof enclosure
103
Installation Methods
FEED
IN
1a
NON-HAZARDOUS AREA
HAZARDOUS AREA
2b
1a,b 5b
6
Typical Conduit 4
1b 2b
Installation 7b
7h
18b
5b 1b 14c
6b 1b
2b 2b Bd
6 5 2b
19k
1b 3jc
5
1b
4
1b
5
18b 5
7b
19d 2b
15 3j
9h 18i
1b
2c
9h 1b
8
15
3j,b
19k
1b
4
13 1b
4 16
17
17
17 13
GAS
FACT
Fluorine is the most reactive
and most electronegative
of the elements, making
elemental Fluorine a
dangerously powerful Oxidant.
This leads to direct reactions
between Fluorine and most
elements, including noble
gases Krypton, Xenon, and
Radon.
Fittings and Seals for Conduit Conduit Seals

The seals prevent any explosions in
the tubing from spreading. Drains
must be installed at low points where
condensation may accumulate.
EXGJH/EXLK UNY
Horizontal Seal
ELF
Packing Fibre Sealing Compound
EYM EYDM
Vertical Seal with Drain
Boxes
Wires
GR GRF Plug
Drain Channel Sealing Compound
Packing Fibre Drain

Conduit
GRSS CPU
105
26 Gas Detection
Maintenance and
Ongoing Care
A vital part of ensuring that fixed and portable gas detection
equipment operates correctly is periodic servicing, maintenance
and calibration. Unlike some other types of safety related equipment
(e.g. fire detection), gas detection does not have specific legislations
or clear guidelines that specify how often it should be serviced.
Relevant documents simply state that maintenance should be carried
out frequently by competent, trained personnel and in line with the
manufacturers recommendations.
Selecting the right service
G
as detection applications but also the industry in which you operate
vary considerably and these provider and regulations. Application-based variables
differences can affect the and legislative requirements (international or
approach to ongoing device When selecting a gas detection solution, it’s national) can impact ongoing maintenance
support and also the frequency of servicing essential to take a holistic view and consider requirements considerably.
required to ensure proper operation and the impact of ongoing device care at the
maximise uptime. gas detection selection stage. This means Question: Do you offer comprehensive service
that a gas detector not only needs to be and support options and the flexibility to meet
It is important that a suitable service period application-suited in terms of its specification my exact needs?
and functionality, but its ongoing maintenance
is established for the equipment that takes
requirements.
account of each individual application’s unique Even if you have in-house support to help
set of factors. Some sites choose to have their you maintain your gas detection system, it’s
own dedicated in-house support to carry out With a variety of manufacturers in the important to find out what services can be
routine maintenance and ad hoc equipment marketplace claiming to offer the leading-edge offered regarding the ongoing care of your
fixes, whilst others choose to outsource this solutions and the best provision of support and system. For example, if a problem occurs, how
care, the process of comparing offerings and
activity to the equipment manufacturer or third quickly can the manufacturer respond? What
choosing the most suitable company to work
party technical support provider. is the provision of field and support resource
with can be an arduous and lengthly process.
they can offer, what services will come as part
As a leading-edge equipment manufacturer and of your package, and what will you need to
complete solutions provider, Honeywell offers It’s important to evaluate any prospective pay extra for? It’s also important to consider
manufacturer or third party service provider
comprehensive technical service and ongoing the structure of the services offered. Can you
against a set of criteria before moving
device support; either directly or through a create a bespoke package of options designed
forwards. The following questions will help you
network of officially approved service partners. to meet your specific requirements or are
gain a valuable insight into whether a supplier
is likely to be able to meet your specific packages more structured and standardised?
When you work with Honeywell or its individual requirements.
approved partner network, you get so much Question: What infrastructure do you offer and
more than just equipment maintenance and what customer support will I receive if I choose
field support; our aim is to operate like an Question: What expertise do you have to work with you?
extension of your business, providing tailored regarding my specific application?
solutions that maximise uptime of equipment Knowing the full resource offering of a
and deliver the flexibility to evolve with your A service provider needs to have an intrinsic prospective service provider is essential; you
changing business needs. understanding of your business and the unique will need to know what resource they have in
requirements in not only your application terms of being able to provide information to
you when you need it. You will also need to Selecting and integrating productivity to the need to modify existing
know the level of customer support you will systems. Experts can help to make the
have access to in terms of order processing
gas detection process of integration as smooth as possible.
and logistical supply of equipment and
A service provider can work with sales
services and whether support will be provided Site Acceptance Testing (SAT): SAT is a
engineers, taking an holistic approach to
in your local language etc. identifying the right equipment solutions full function test conducted on site with all
and also help with a seamless integration new gas detection equipment to check its
Question: Will you provide customer service that has a minimal impact to site performance.
and ongoing device support to me in my local operations.
language, taking into consideration my local Site evaluations: A site evaluation can Commissioning: It is always advisable to use
customs and regulations? be particularly beneficial - especially for competent and product trained Engineers
customers that are unfamiliar with fixed to ensure correct installation and operation.
Everyone likes to work in ways that are gas detection options available. Professional commissioning also preserves the
familiar and language, cultural and legislative Expert assistance and site analysis can help manufacturer’swarrantyandpreventswarranty
differences are particularly important; to define where gas detection is needed loss through damage resulting from incorrect
especially when it comes to highly technical and what types of solutions may meet the set-up.
products like gas detectors. requirements of the plant.
Ongoing device maintenance

Application engineering: Assistance to help
Ongoing support services
define the best solutions within the context Planned maintenance regimes can greatly
The most obvious aspect of ongoing device of the application and its variables. benefit sites by limiting the chances of ad hoc
care is maintenance and equipment fixes issues that can adversely affect productivity,
(should they be required), but in reality, these System integration: For sites that already so the right philosophy to ongoing device
aspects only form a small part of all the have safety systems, guidance can be care can help to maximise uptime and help to
services that are offered to gas detection provided to select the right gas detection prevent potentially costly shutdowns.
users. A good service provider will be able to elements to integrate into the existing
guide you from the earliest stages of identifying system. Field maintenance: Field assistance is
needs and selecting equipment right through
ideal for sites where dedicated maintenance
to supporting your product for the whole of its
Pre-installation support: After choosing gas personnel are not available and helps to ensure
operational life.
detection, consideration needs to be given that equipment is maintained and correctly
to receiving and integrating the equipment. working. Field teams can carry out planned
Commissioning new equipment can impact maintenance activities or ad hoc equipment
upon various aspects of the plant; from its repairs on site.
107
Gas Detection Maintenance
and Ongoing Care (continued)
Preventative/corrective maintenance: As the headcount, it may be preferable to have this support will not limit their assistance to
saying goes, prevention is always better than support provided by a third party. A good just their own products. When selecting
cure and the same applies to the care of gas service provider will be able to offer on-site a support provider, it’s worth considering
detection equipment. Rather than waiting until support if required. their ability to repair other gas detection
an issue occurs (which could adversely affect devices you might have on site, so you
productivity), a planned maintenance scheme Mobile Calibration: Carrying out routine only need to work with a single supplier.
can maximise uptime and greatly limit the calibration of devices doesn’t have to have a
potential of ad hoc issues occurring. In fact, big impact – in fact, a service provider who Additional Extras
market research shows that a preventative offers a mobile calibration service for portables
maintenance regime can limit the number of can help to greatly limit plant process Aside from the more traditional services, many
equipment related issues by as much as 50% interruptions. Devices can be brought down suppliers are able to add value in additional
in the first 90 days. to a calibration vehicle for the work to be ways:
carried out on site.
Workshop repairs: When devices need repair Support documentation: Sites have to
work, it’s important that they are fixed within 24/7 emergency call out: If the worst keep records of compliance certificates
the stipulations of their warranty (i.e. work is should happen and you need immediate and documentation. A good equipment
carried out by the equipment manufacturer or support, a good service
an approved service provider, certified by the provider will be able to
manufacturer to carry out such work).
When sending an item back for repair, it’s
offer emergency help
(whether it is provided
How to preserve your warranty
essential to work with a service provider who technically over the
As previously mentioned, it’s essential to follow the conditions
can provide quick turnarounds, to minimise phone, by email or in
in any product warranty (including installation, commissioning
device downtime. person). and repair). Failure to adhere to such conditions can invalidate
a warranty. One benefit of using technical support from some
Resident, on-site maintenance: For the most Repair and maintenance product manufacturers like Honeywell is the added-value of
demanding applications, where downtime of third party having a Manufacturer’s Work Warranty Compliance Certificate.
needs to be minimised wherever possible, equipment: Many good This provides peace of mind that all work is within warranty
a resident on-site expert may be required. manufacturers who offer condition, preserving your warranty.
Depending on your business approach to service and ongoing
Honeywell Gas Detection | The only service provider you’ll ever need
We offer a single source solution to technical service and ongoing At Honeywell Gas Detection, we pride ourselves on offering the highest
device support. quality of customer support. This enables us to provide excellent lead
times and the assistance our customers need; from initial product enquiry
At Honeywell Gas Detection, we have a detailed understanding of all right through the whole product life.
gas detection applications and this means that we are able to identify
and react to the specific needs of your business. In fact, we have a team Why work with Honeywell?
of application specialist engineers who can provide the expertise you Honeywell is a pioneering force within the life safety industry, innovating
require to help identify exactly what you need and then find a solution benchmark products that set the standard for workplace safety:
that meets those specifications.
• We produce advanced devices and solutions that help to reduce the
We understand the importance of good onward care, and with this in ongoing cost of workplace safety
mind, we offer a rich resource of engineering and workshop support. • We provide World class service and support for gas detection
This means that if you need assistance, we can help you quickly and • All our products are designed to meet specific market needs and
efficiently, maximising your process uptime. The support we offer is also we work directly with industry and our clients to evolve solutions
highly flexible and you can pick and choose options to create a bespoke designed to meet requirements
package that meets your business needs. In fact, we even support third
party gas detection equipment. If you would like further information on Honeywell’s technical service and
ongoing support options or those offered by Honeywell’s approved partner
network, please contact us on +41 (0)44 943 4300 or email
gasdetection@honeywell.com.
manufacturer will keep records of this
information and be able to provide you with
copies should you need information at a
later date.
Custom drawings and CAD designs:

For unusual applications or complex sites,
bespoke drawings can be useful, when
integrating new equipment. A good service
provider can work with you and generate
customer drawings and CAD designs, helping
to ensure equipment can be successfully
integrated into your site.
Expert end-to-end technical

service
and support
Europe +41 (0)44 943 4300
Americas +1 800 538 0363
Asia +82 (0)2 6909 0300
109
Glossary
ACGIH American Conference of Governmental Industrial Hygienists.
AIT Auto Ignition Temperature.
Analogue/analog output Standard mA output from a sensor or transmitter. Normally described as 4-20mA.
The alternative is a mV bridge output from a catalytic type sensor.
Apparatus group The classification of flammable gases into groups that are associated with required
apparatus design standards.
Asphyxiation Death resulting from lack of Oxygen.
ATEX European Explosive Atmospheres Directives (ATmosphere EXplosives).
Baseefa British Approvals Service for Electrical Equipment in Flammable Atmospheres –
UK Safety Certification.
BMS Building Management System.
Binary mixture of gas A mixture of two gases only.
Breathing zone 10 In/25cm radius from the nose and mouth.
Bridge circuit Wheatstone Bridge circuit used in catalytic detector design.
CAS number Chemical Abstracts Service. CAS registry number used to identify substances
without the ambiguity of chemical nomenclature.
Calibration The process of adjusting the output of the detector to give an accurate reading of
gas concentration over its measuring range.
Carcinogenic Capable of causing Cancer.
Catalytic sensor For detection of combustible gases. These are made of an electrically heated Platinum
wire coil, covered first with a ceramic base such as alumina and then with a final outer
coating of Palladium or Rhodium catalyst dispersed in a substrate of Thoria.
CE Indicates compliance to all relevant European directives.
CEC Canadian Electrical Code.
Cell An individual sensor.
CENELEC Comité Européen de Normalisation Électrotechnique.
Cesi Centro Elettrotecnico Sperimentale Italiano – Italian Safety Certification.
Channel One line or point of gas detection.
Chemcassette® Registered name of a paper tape cartridge used in toxic gas analysers.
Conduit Metal tubing mainly used in the US for installation of wires in hazardous areas.
COSHH Control of Substances Hazardous to Health.
CSA Canadian Standards Association.
dBA Decibels, relative to the A weighting scale (as affected by the human ear).
DCS Distributed Control System.
Domestic gas detector Gas detector designed specifically for use in domestic or residential properties.
Division North American area classification of a hazardous area (Division 1 or 2) that defines
the length of time a hazard is present.
Electrochemical cell sensor Electrochemical sensors are essentially fuel cells composed of noble metal electrodes
in an electrolyte.
EMC Electromagnetic compatibility.
ESD Electrostatic discharge.
Ex d Hazardous Area Design Standard “Flameproof”.
Glossary continued
Ex i Hazardous Area Design Standard “Intrinsically Safe”.
Ex e Hazardous Area Design Standard “Encapsulation”.
Ex m Encapsulated to keep gas out of product. Zones 1 and 2.
Explosimeters Combustible gas monitor.
Explosion-proof A name for Ex d apparatus design.
EXAM Hazardous Area Approvals body based in Germany.
Fail safe Description of a detector that has no unseen failure modes.
Fieldbus Digital communication standard.
Firedamp A mixture of methane and other Hydrocarbon gases that forms in coal mines.
Fixed point system Gas detection system using individual fixed point gas sensors and / or transmitters.
Flame arrestor A structure that allows gas to diffuse through it into a detector but prevents propagation
of any flame back out.
Flameproof A name for Ex d apparatus design.
Flammable range The band in which a gas/air mixture is flammable.
Flash point This is the lowest temperature at which vapour is given off at a sufficient rate to form
an explosive mixture with air.
FM approval Factory Mutual – USA Safety Certification.
Gas analyser Normally refers to equipment used to measure extremely small concentrations of gas
(low or ppb) or one specific gas in the presence of several others.
Gas detector Refers to equipment used in applications where there is normally no toxic or explosive
gas risk and therefore is used to signal the presence of gas in otherwise safe conditions.
Gas monitor Equipment used in applications where a gas or gas mixture is constantly present and
is therefore used to signal a change in the concentration or mixture of the gas.
GOST Russian hazardous area approvals body. Widely accepted in Eastern Europe or as a
base for own local approvals.
Hazardous areas Areas where there is the possibility of the presence of an explosive mixture of
flammable gas or vapour and air are known as ‘Hazardous’ and other areas as ‘safe’
or ‘non-hazardous’. Any electrical equipment used in hazardous areas must be
tested and approved to ensure that, in use even under fault conditions, it can not
cause an explosion.
HSE Health and Safety Executive (UK).
Ignition temperature The lowest temperature that will cause a mixture to burn or explode.
Ineris Institut National de l’Environnement Industriel et des Risques.
Infrared detector Gas detector that uses the principle that infrared light is absorbed by gas molecules
at specific frequencies.
International Electrotechnical International Standards and conformity assessment for government, business and
Committee society for all electrical, electronic and related technologies.
Intrinsically safe (IS) Method of design so that the maximum internal energy of the apparatus and wiring
is not sufficient to cause ignition by sparking or heating effects resulting from a fault.
IP Ingress Protection – a measure of protection against the ingress of dust and water.
LCD Liquid Crystal Display.
LED Light Emitting Diode.
LEL Lower Explosive Limit – the lowest concentration of ‘fuel’ in air which will burn and
for most flammable gases and vapours it is less than 5% by volume.
111
Glossary continued
LEL% Percentage of the Lower Explosive Limit (for example, 10% LEL of Methane is approx
0.5% by volume).
LEL metres Scale for measurement for flammable gases by open path infrared detectors.
LFL Lower Flammable Limit.
LNG Liquefied Natural Gas.
LPG Liquefied Petroleum Gas made up of Propane and Butane.
LTEL Long Term Exposure Limit. The 8 hour LTEL is the time-weighted average concentration
for a normal 8 hour day to which most workers may be repeatedly exposed, day after
day, without adverse effect.
mA Milliamp – measurement of current.
MAC Maximum Allowable Concentrations (replaced by TLVs) - toxic gas levels
described by ACGIH.
MAK Maximale Arbeitsplatz Konzentration.
MEL Maximum Exposure Limit.
Milligrams per cubic metre Alternative unit of measurement for toxic gases.
ModBus ModBus is a serial communication protocol published by Modicon in 1979 for use with
its programmable logic controllers (PLCs).
Multi-channel More than one gas channel.
Multi gas Portable gas detector with typically up to 4 gas sensors fitted.
mV Millivolt – measurement of voltage.
Natural gas Fossil fuel formed almost entirely of Methane.
NEC 500 National Electrical Code (US).
NEC 505 Latest version of NEC.
NEMA National Electrical Manufacturers Association. US standards developing organisation.
NEMA rating of enclosures is similar to the IP rating system.
NIOSH The National Institute for Occupational Safety and Health.
NRTLs Nationally Recognised Testing Laboratories (US).
OEL Occupational Exposure Limit – The 8 hour OEL is the time-weighted average
concentration for a normal 8 hour day or 40 hour working week to which most
workers may be repeatedly exposed, day after day, without adverse effect.
Open path Open Path gas detectors are comprised of a transmitter and receiver, separated by a
range. The transmitter sends out a beam of Infrared light, detecting gas anywhere along
the path between the transmitter and receiver. The path can be anywhere from a few
metres to a few hundred metres in length.
OSHA Occupational Safety and Health Association.
Oxygen deficiency Concentrations of Oxygen less than 20.9% V/V.
Oz Ounce (weight).
Peak The maximum or minimum measurement since switch on.
Perimeter monitoring Monitoring the outer edge of a plant or storage area as opposed to monitoring
specific points.
Pellistor Registered trade name for a commercial device – a very small sensing element used
in catalytic sensors and sometimes also called a ‘bead’ or a ‘siegistor’.
PLC Programmable Logic Controller.
Glossary continued
PELs Permissible Exposure Limits (OSHA).
Point detection Detecting or measuring gas at a fixed point/position.
Poison resistant Capability of a catalytic sensor to reduce the effect of inhibiting substances or
contaminants, such as silicones.
PPB Parts per billion concentrations in the atmosphere.
PPM Parts per million concentrations in the atmosphere.
PTB Physikalisch Technische Bundesanstalt.
RELs Recommended Exposure Levels (NIOSH).
Response curve The line that shows detector response to gas at points over time.
Retro reflector Reflecting panel that returns an infrared signal.
RFI Radio Frequency Interference.
RH Relative Humidity.
RS485/232/422 Digital communication protocols.
SAA Standards Australia Quality Assurance Services Pty Ltd. Australian safety certification.
Safe area Work area in which there is no danger of contamination with explosive gases.
Semiconductor sensor Type of sensor that uses semiconductor material in construction.
SIL Safety Integrity Levels.
Single channel One point of gas detection.
Sira Sira Test and Certification Service (UK).
Smart Used to describe a sensor with a processor that communicates a signal and is able to
execute logical functions.
Span The level at which calibration is made (typically 50% of full scale).
STEL Short Term Exposure Limit, usually monitored over 15 minute periods.
T90 Time taken for a detector to reach 90% of its final reading.
T60 Time taken for a detector to reach 60% of its final reading.
Temperature Relates to the maximum surface temperature apparatus is allowed to have. This is to
classification/class ensure that a device cannot match or exceed the ignition temperature of the gases or
vapours that may be present in the environment.
Thermal conductivity Method of detecting the level of gas using its properties of thermal conductivity.
TLV Threshold Limit Value.
TWA Time-Weighted Average.
UEL Upper Exposure Limit.
UL Underwriters Laboratories (USA).
%VOL Concentration of explosive gas, measured in percentage by volume.
V/V Another way of representing %VOL.
Vapour density A measure of the density of gas or vapour relative to air. Gases or vapours with a
vapour density less than 1 are lighter than air.
WELs Work Exposure Limits (EH40).
Zone Area classification of a hazardous area (Zone 0, 1 or 2) that defines the length of time
a hazard is present. Mainly used in Europe.
113
Notes
115
Find out more
www.honeywellanalytics.com
Contact Honeywell Analytics:
Europe, Middle East, Africa, India

Life Safety Distribution AG
Javastrasse 2
8604 Hegnau
Switzerland
Tel: +41 (0)44 943 4300
Fax: +41 (0)44 943 4398
India Tel: +91 124 4752700
gasdetection@honeywell.com
Americas
Honeywell Analytics Inc.
405 Barclay Blvd.
Lincolnshire, IL 60069
USA
Tel: +1 847 955 8200
Toll free: +1 800 538 0363
Fax: +1 847 955 8210
detectgas@honeywell.com
Asia Pacific
Honeywell Analytics Asia Pacific
#701 Kolon Science Valley (1)
43 Digital-Ro 34-Gil, Guro-Gu
Seoul 152-729
Korea
Tel: +82 (0)2 6909 0300
Fax: +82 (0)2 2025 0328
analytics.ap@honeywell.com
Technical Services
EMEAI: HAexpert@honeywell.com
US: ha.us.service@honeywell.com
AP: ha.ap.service@honeywell.com
www.honeywell.com
Please Note:
While every effort has been made to ensure
accuracy in this publication, no responsibility
can be accepted for errors or omissions.
Data may change, as well as legislation, and you
are strongly advised to obtain copies of the most
recently issued regulations, standards, and guidelines.
This publication is not intended to form the
basis of a contract.
H_Gasbook_V5
04/13
© 2013 Honeywell Analytics
www.honeywellanalytics.com/www.gasmonitors.com

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GasBook

Honeywell Gas Detection

A diverse variety of applications

1 Introduction 2 18 ATEX 80-81

Working with Industry…

Delivering value added solutions at

As a leading expert in the field of portable gas detection, we provide

When it comes to device care, we also offer cost-effective benchmark

The name gas comes from the word

Different gases are all around

Gases can be lighter,

FLASH POINT (F.P. °C)

Gas / Vapour Flash Point °C Ignition Temp. °C

Gas/Vapour Vapour Density

Occupational Exposure Limits in the UK

As of 6 April 2005, the regulations introduced

Maximum Exposure Limits (MELs) and

500 = Feeling ill

Occupational Exposure Limits Comparison Table

Common Name CAS Number Formula

EH40 Workplace Exposure Limit (WEL) OSHA Permissible

ppm mg/m3 ppm mg/m3 ppm mg/m3

0.02 0.03 0.1 0.13 1 1.3

1 1.4 2 2.8 1 1.4

Common Name CAS Number Formula

ppm mg/m3 ppm mg/m3 ppm mg/m3

0.5 0.67 1 1.3

50 191 150 574

(Oxygen Deficiency) • Combustion

It is often forgotten that Oxygen enrichment can also

Oxyacetylene welding equipment combines

Sensors have to be specially certified for use in

Water treatment Marine Military and Pulp and paper

Printing Semiconductor Photovoltaics Confined spaces

Ammonia Steel Mills Agriculture and live Commercial

Modern combustible gas detectors have to be much

Non-sensitive This type of sensor operates on the principle

(N.B. In the USA and some other countries,

A further improvement in stable

Typical types of gas sensor/transmitter

Sensor screwed to Sensor screwed to Sensor screwed to Transmitter with remote

Older (and lower cost) systems require

Infrared Gas Detector

The technique operates on the principle of

Open Path Flammable

gas/false alarm gas/fault

Double reference design – fully compensates

Solid state detectors

Electrochemical sensors are compact, require

Commercial designs of electrochemical cells Counter electrode

Three active gas diffusion electrodes are Second expansion

Photo Ionised Detection (PID)

Comparison of Gas Detection Techniques

Performance in Yes Yes Yes Yes No Yes No

Consideration will also need to be given

A holistic approach needs to be adopted

XNX Universal Transmitter

Series 3000 MkII and MkIII

Sensepoint XCD RFD Signalpoint Pro