Gas Detection 35 CO2 Gas Hazards in the Brewing Industry


The hazards associated with CO2 in the brewing industry are well known, yet people still die needlessly every year in tragic and completely avoidable accidents in breweries. Just last year in Germany, which has a good safety record, two workers died in separate incidents at the same brewery.


Chris Wilson, Crowcon’s (UK) Senior Support Engineer, discusses these incidents and explains how they could have been avoided by following the right CO2 gas safety procedures.


CO2 is extremely hazardous and can kill in two ways: either by displacing O2, leading to rapid asphyxiation, or as a toxin in its own right. Exposure to as little as 0.5% volume CO2 represents a toxic health hazard, while concentrations greater than 10% volume can lead to death. Because CO2 is completely odourless and colourless there is no physical indication of danger until it is usually too late.


CO2 is a by-product of the fermentation process and, because the gas is heavier than air, it collects at the bottom of containers and confined spaces such as tanks and cellars and can even spill out of fermenting tanks and sink to the brewery floor, where it forms deadly, invisible pockets. In fact, CO2


is a hazard throughout the brewing process, right through to packaging and bottling.


Fermentation tanks, beer mixing tanks, silos and other confined spaces in the brewing industry are easily accessible – it is rare for them to be fitted with safety interlocks. For this very reason rigorous safety systems should be in place and always adhered to. Employers must assess the risks these areas pose to their employees and endeavour to prevent them. In most cases, both the assessment and the safe working system will require testing of the atmosphere with gas detection equipment.


As a rule, entry should not be routine and should only be carried out if absolutely necessary. However, if entry is necessary – for example for an inspection or to ensure cleaning has been carried out correctly – suitable safety procedures must be followed.


Firstly, CO2 from the space must be completely removed. This can be done by discharging all the fermentation and pressure gasses directly into the open air using a ring main system. If this is not possible due to the layout, the CO2 must be manually extracted and safely diverted.


Prior to entering a tank or other confined space, a ‘release measurement’ of CO2 must be taken using a suitable CO2 monitor. This is the only reliable method to check whether the CO2 concentration is actually at a safe level. The measurement must be taken by a qualified person, usually by lowering the monitor into the chamber and leaving it there for several minutes. It goes without saying that any


monitoring device must be durable, reliable and regularly calibrated and tested.


Anyone entering a tank or other confined space must also be equipped with a suitable gas detector. If a certain CO2 concentration is exceeded the device will go into alarm mode with both audio and visual alarms. Generally, at a CO2 volume of 0.5 % by volume, a pre-warning is set off; at 1 to 2 % by volume the main alarm is activated. With most devices other alarm thresholds can be selected with the aim of avoiding the alarm sounding too frequently and simultaneously ensuring the safety of the person working in the container.


Both portable and fixed CO2 detectors can be used for CO2 monitoring in breweries. Fixed systems typically comprise one or more detector "heads" connected to a separate control panel. If a detector reads a dangerous CO2 level, extractor fans are automatically triggered and sirens or visual beacons can also be activated to warn workers to vacate the area. This sort of installation is suited to larger spaces like cellars and plant rooms.


However, much confined space work in the brewing industry takes place in more restricted areas like fermentation tanks where fixed detectors cannot be installed. This means compact portable units are required. Ease of use, with one button operation, should be the norm when it comes to portable detectors. This means minimal training is required while increased safety is ensured. Combining one or more sensors with powerful audible and visual signals to warn when pre-set gas levels are reached, compact portable detectors are easily carried in a confined space, ensuring that pockets of high CO2 concentration are not missed.


Certain features should be expected in every portable CO2 detector. Clearly, life-saving tools for demanding environments must be as tough as possible, with reliable electronics housed in impact-resistant casings. While the need to leave gas sensors exposed to the atmosphere means that no instrument can be fully sealed, a high degree of protection against dust and water ingress is essential. Toughness


notwithstanding, a well-designed detector will also be light and compact enough to wear for an entire shift.


Finally, because of the difficulties of working in a cramped space, perhaps under poor lighting, instruments should be easy to use. No matter how advanced a detector's internal architecture or data management options, personnel in the field should be faced with nothing more daunting than a clear display, simple, one-button operation and loud/bright alarms.


Not taking the risk of CO2 seriously has led to many unavoidable deaths. If all the safety procedures described above are observed, the risks of dealing with this colourless, odourless and tasteless gas can be significantly reduced.


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Toxic Gas Detector Receives IECEx Approval


The TS4000H Intelligent Toxic Gas Detector from General Monitors (USA) is now IECEx approved, informing General Monitors’ customers the TS4000H has been independently evaluated and found to be in compliance with international safety standards for explosive environments. The TS4000H offers protection against a wide range of hazardous industrial gases and is able to safeguard against oxygen deficiency.


The International Electrotechnical Commission (IEC) established the IECEx mark to facilitate international trade in equipment for explosive atmospheres and hazardous locations. Benefits to IECEx approval include reduced testing and certification costs to the manufacturer, reduced time to market, international confidence in the product assessment


process, one international database listing and increased international confidence in IECEx-certified equipment and services. GeneralMonitors’ customers can be assured that the TS4000H and its manufacturing facilities have been and will continue to be independently assessed for compliance with rigorous international standards.


With its advanced design, the TS4000H Toxic Gas Detector offers many valuable features including event logging, a clearly visible LED, and an indicator for remaining sensor life. The TS4000H is compatible with the HART communications protocol for uniform and consistent communication without disturbing the integrity of the 4-20 mA analogue signal, and is also available in a Modbus configuration and with three 8A relays. All of the electronics are contained within an explosion-proof housing so that sensor information


can be processed at the sensor site.


Additionally, the interface module’s galvanically-isolated, intrinsically-safe design supports sensor field replacement without special tools or hot work permits. Furthermore, the detector is easy to install and can self calibrate by activating a magnetic switch and applying gas. Process engineers who need to protect people, equipment, and the environment will find the TS4000H well suited for a broad range of industries: Petrochemical installations, oil and gas production facilities, water and wastewater treatment sites, and power plants are some of hazardous environments to which the TS4000H can add great value. For worldwide application, the detector also complies with ATEX, CSA, CE, GOST in addition to IECEx, and is certified for use in SIL 2 environments.


The TS4000H monitors a variety of toxic gases like ammonia, carbon monoxide, chlorine, chlorine dioxide, hydrogen, hydrogen chloride, hydrogen sulphide, nitric oxide, nitrogen dioxide, oxygen deficiency, ozone, and sulphur dioxide. The system displays gas concentrations up to 500 ppm, fault codes for troubleshooting, prompts when calibration is needed, and provides complete status to the control room.


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Gas Detection Market Reaches $2.2 Billion in Annual Revenues


New market trends data released by Honeywell company City Technology (UK) shows extensive growth in the Industrial Gas Detection sector, which has now reached $2.2 billion in worldwide revenues. The biggest growth in the sector has been attributed to the Oil and Gas industry, spurred on by a surge in Shale Gas exploration and the increasing demand for energy.


City Technology is at the heart of Gas Detection systems, providing specialist solutions in gas sensing technology, ensuring safety in the sector. City are specialist suppliers of gas sensors for the life safety and emissions gas analysis sectors, contributing to a global gas sensing market worth $420m.


John Warburton, Strategic Marketing Manager at City Technology, describes this market as vibrant with many opportunities for continuing growth. "The Gas Detection market is very strong at the moment. For example, we are predicting that the global demand for gas sensors will grow at 5-6% pa over the next five years with the Asia Pacific region growing at 10%. Growth in North America will remain strong, driven by the on-going development of shale gas deposits.


“Moreover, new trends in Gas Detection go beyond traditional markets. For example, City has highlighted the growth in the market for Medical and Domestic Gas Detection sensors, for instance in carbon monoxide and flammable gas alarms, which are worth nearly $90 million combined." John Warburton affirms that, “These future growth markets are being driven by health and safety awareness and legislation. Furthermore, it will be an increasing demand for energy and the strengthening global economy that will shape these developments and, therefore, the future of gas detection.”


With a range of more than 300 products detecting 28 different gases and a growing number of facilities in Europe, the USA and Asia Pacific, City Technology is well positioned to capitalise on this market growth whilst continuing to be the leading choice for sensing technology.


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