6 Safety
Universal Truths: Evaluating Next-Generation Gas Detection
Designing, Implementing and Maintaining A Truly Universal Approach To Gas Detection.
Daniel Munson, Byron McClendon, Scott Safety Tel: 800-247-7257 • Email:
scottsafetymeridian@tycoint.com • Web:
www.universalByScott.com
Protecting your people and your physical plant, while ensuring business continuity, are the most important functions of a fixed gas detection solution. Engineering a reliable, high-performance system that makes it easier and more cost effective to meet this challenge is the driving force behind a truly universal approach to gas detection.
Tis white paper is about the evolution and benefits of designing, implementing and maintaining a truly universal approach to gas detection. Our intention is to help you use this information, based on “universal truths,” to evaluate your current system and project the impact of next-generation gas detection on your organisation’s safety and productivity in a global economy.
In a global economy, the challenges to personal safety, productivity, and business continuity are magnified. Companies in a wide range of industries, where the presence of combustible and toxic gases are a way of life, must continue to evaluate their gas detection systems or pay the price on many levels. This evaluation must consider a number of factors that can enhance safety, whilst streamlining installation and minimising maintenance – in the present and the future. That’s what constitutes a truly universal solution.
Fixed Gas Detection with Legacy Technology/Instruments
Before we look ahead and evaluate a truly universal approach, it’s important to take a look at how gas detection is done with legacy technology today…
• a single detector is paired and tested with a single sensor, detecting only a single combustible or toxic gas
• adopting new, advanced digital communication protocols necessitates replacing existing systems with new detectors and/or new sensors
• unique certification requirements for different devices and regions complicate the ability to engage in business as a company expands its operations globally
• more points mean more maintenance and associated costs
• a field technician’s toolbox is packed with multiple sensors, detector heads and accessories from multiple manufacturers, requiring major inventory investment
• a large workforce with specialised knowledge is needed to address specific installation and service requirements; and multiple manuals, covering many different product lines, only complicate installation and impede productivity
Engineering, Installation and Maintenance for a Universal World
Call it a paradigm shift in response to customer needs. Today, there is an increasing call for higher levels of safety, performance, standardisation, economies of scale, ease of use, and overall accountability. Meeting these needs and adding value to the customer experience begins with re- thinking fixed gas detection engineering.
Engineering a universal gas detection system provides its own set of challenges. But these challenges are being met and needs are being fulfilled. As you position your company to leverage a truly universal gas detection solution, you must evaluate where you are and where you need to be. The following exploration of legacy systems used in the field today and truly universal characteristics of next-generation gas detection instruments should aid in your evaluation.
One to Many
Legacy System: A single detector is paired with—and tested with—a single sensor, accommodating only a small number of combustible or toxic gases.
Truly Universal System: A single gas detector accommodates multiple sensors, allowing you to detect multiple types of gases in one location. Working within the same device footprint the transmitter is designed to support different sensing technologies: combustible gas sensing with infrared and catalytic bead sensors and electrochemical and metal oxide semiconductor sensors for toxic gases. Using equally smart sensor technology allows the construction of sensors with
multiple ranges in the same package which in turn enables range invariant calibration. One instrument that can provide the capabilities of multiple instruments, and one sensor that can support multiple gas ranges provides valuable flexibility not available in legacy gas detection devices.
Communication Protocols
Legacy System: Legacy systems have traditionally relied on analogue signals for communication. This limits the transmission of advanced diagnostics data that ensures a safe plant environment. Adopting digital communication protocols necessitates installing new detectors and/or new sensors.
Truly Universal System: As needs change and new communications protocols are required, universal transmitters are engineered to accept new plug-and-play communication boards. This multiprotocol innovation – wired or wireless (when industry appropriate) – means protocols can be added without replacing the transmitter as a plant’s communication requirements change. You’ll want to make sure your enterprise accommodates a wide range of communication protocols, including Modbus, HART, wireless HART and wireless ISA100.11A. This kind of flexibility is a key to a future-proof gas detection solution, and the transition from rigid, proprietary systems to standards-based, secure systems that accommodate growth and change.
Calibration and Maintenance
Legacy System: Because of engineering constraints, sensor calibration must be performed in the field, where conditions are less than ideal and both safety and performance may be compromised.
Truly Universal System: Accurate calibration is critical to satisfying both safety and performance requirements. It also impacts productivity when false alarms, due to inaccurate calibration, slow down – or even shut down – production. Imagine the consequences of an electrochemical sensor triggering an alarm that releases a blanket of foam. The cleanup costs alone can be staggering!
Next-generation gas detection enables a calibration-in the-lab scenario, providing a more controlled and safe environment for establishing gas sensor parameters. This is a significant innovation, especially with legacy cat bead sensors which required proper
AUGUST / SEPTEMBER 2013 •
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