Gas Safety in Small Industrial Facilities: Key Steps

The use of gases is essential to a wide range of manufacturing and production processes, from fermentation to refrigeration, disinfecting to packaging processes. However, while these gases may be vital to a wide range of process industries, they also pose significant hazards. As a result, the implementation of a reliable gas detection system in these settings is imperative to ensure the safety of the workforce, corporate assets, and the environment.

The approach used may depend on the complexity of the setting and, as a result, this is likely to be different in a smaller manufacturer, boiler room or science laboratory than it would be in a large chemical production facility.

The wide variety of gases and the different ways they are used, combined with the potential high-risk nature of the hazards involved, can make gas safety seem a challenging area, further complicated by regularly evolving legislation and advice.

“Above a certain concentration, hydrogen sulphide damages the nasal receptors, making safe detection impossible without proper monitoring technology.”

As a result, it can be difficult to know the best approach to take to ensure the safety of workers, and more broadly, any specific business facility or operation. This is particularly true in smaller settings, not least because in such environments, health and safety knowledge (and resources) may be more limited, in stark contrast to, for example, a multinational petrochemical company, which may well have a large global health and safety team with specialists in gas detection.

The ability to find the right gas detection system for the task and work in partnership with an experienced and reputable provider to find the best solution can be particularly valuable within smaller or less complex facilities.

Boiler Room Safety Example

If we consider a boiler room, a facility which is present in almost all process industry settings to generate heat, cooling and power, the presence of gases and the potential for gas leaks pose a significant safety risk.

These gases can include natural gas (methane), carbon monoxide, and, where steps are being taken to reduce carbon emissions, hydrogen or hydrogen blends. Constant monitoring is needed so that any leaks can be detected immediately and enable action to be taken and accidents to be prevented.

Both methane and hydrogen are lighter than air and will rise if released, so detectors for these gases should be installed at high level, close to potential leak points such as valves, pipe joints and the boiler itself. In cases where hydrogen is present, its high flammability may also require the addition of appropriate flame detection as part of the safety system.

Where multiple gases are present in a boiler room, a modular system may be installed to monitor for different gases, where they are present.

Regardless of the type of boiler room set-up, a small control panel will be installed outside the room, which is straightforward to operate and shows the status inside the room.

“Gas detection of airborne hazards is an issue that is attracting growing focus, not least with the increased use of new and more environmentally sustainable practices and materials.”

Key Principles for Effective Gas Detection

If there is a leak, the gas detection system can act to shut off the gas supply, thus preventing the situation from escalating, and at the same time signal to shut off the electrical supply to help remove potential ignition sources.

At the same time, an alarm will sound and there will be a visible alarm via a flashing light so that the area can be secured.

Understandably, many organisations approach the topic of gas safety, at least initially, relying, in part, on their existing knowledge of the topic. However, much of the commonly known facts about gas safety are inaccurate.

Understanding Misconceptions About Gas Safety

A good example is hydrogen sulphide. Because of its well-known ‘rotten eggs’ smell, many think that a leak or build-up would be obvious, but this is not the case. Above a certain concentration, hydrogen sulphide damages the nasal receptors, making safe detection impossible without proper monitoring technology.

Specific training on gas safety – particularly the gases relevant to your setting or facility – is often an invaluable way of helping to correct these types of misconceptions. 

Fixed vs Portable Gas Detection Systems

Another key issue to be aware of is that different types of monitoring and detection devices are needed for different settings and applications. For example, a common mistake (or ‘work- around’) is for portable personal gas monitoring devices to be used instead of a permanent point detector.

Portable monitors are battery-powered, which introduces an opportunity for human error if they are not sufficiently charged, and they are therefore unsuitable for constant monitoring requirements. 

Additionally, their alarms are designed to be heard or seen when worn about the person, so they are not sufficiently loud to warn someone on the other side of a room, or other large space. Most importantly, they cannot warn an operative when an area is safe to enter (outside of that space) without having to enter the hazardous area in the first place.

“Using fixed permanent gas detection removes the opportunity for human error, or risk taking in situations where, for example, a portable device may have run out of charge.”

Using fixed permanent gas detection removes the opportunity for human error, or risk taking in situations where, for example, a portable device may have run out of charge, but due to operational or production pressures, the temptation might be to enter an area of risk anyway, on the assumption that it’s only for a short time. There have been cases of this happening where carbon dioxide has been present (a largely odourless and colourless gas) and fatalities have occurred as a result.

A gas detection device should be easy to use and provide the right functionality for the task.

Top Tips for Implementing Gas Safety in Smaller Facilities

1. Keep it simple – particularly for smaller industrial settings. A well-chosen gas detection system supported by expert advice from a knowledgeable provider is often more than enough for lower-complexity environments.
   
2. To this end, work with the company supplying the gas detection system to minimise touchpoints so that the diagnostic information and configuration of the transmitter can be read directly from a controller. This allows for a single touchpoint, which is easy to access and can be linked to an alarm which sounds if there is a leak to activate swift evacuation of the building. 
   
3. Ask the company with which you are considering working what experience they have in your industry, and make sure that they can handle the full range of gas safety issues in your business. Additionally, ensure the company has strong engineering, installation and service and maintenance capabilities to support you through the process and look after your system longer-term.
   
4. Consider the total cost of ownership of gas detection and monitoring devices – quality can vary, and it’s important to ask, for example, how long consumable parts such as sensors or batteries should last – there can be significant differences in the lifespan of such parts, and the frequency with which they may need to be replaced can make the difference between good and poor value in the long term.
   
5. Be alert to ‘workarounds’ in your organisation. Sometimes, particularly in smaller settings, people can be complacent about gas safety and take matters into their own hands. For example, in a food processing factory where carbon dioxide and nitrogen is used in the packaging process (both gases pose serious risks at certain concentrations), simply opening a door to ventilate the area and prevent gases building up is not an adequate safety solution, nor an alternative to the installation of a fixed gas detection system that alerts staff to the potential build-up of harmful gases and keeps the workforce safe.

Conclusion: Partnering for Peace of Mind in Gas Safety

Gas detection of airborne hazards is an issue that is attracting growing focus, not least with the increased use of new and more environmentally sustainable practices and materials. Obtaining good advice from trusted partners is an effective way for health and safety professionals to efficiently address gas safety concerns, from the small and simple to the sophisticated and bespoke, ensuring peace of mind for all concerned.