Understanding Gas Detector Sensor Selection
Selecting the correct gas detector sensor for industrial environments requires matching the technology to the specific gas type, environmental conditions, and application requirements. Not all sensors perform equally under varying temperatures, humidity levels, or exposure to interfering gases. The core of any effective gas detection system lies in the sensor’s ability to accurately convert gas concentration into a measurable electrical signal.
The most common gas sensing technologies include catalytic combustion, infrared (IR), electrochemical, semiconductor, and photoionization (PID). Each has distinct performance characteristics, limitations, and ideal use cases. For example, catalytic sensors are widely used for detecting combustible gases like methane and propane but are susceptible to poisoning by silicone compounds and sulfur. In contrast, infrared sensors offer longer lifespan and immunity to poisoning, making them suitable for harsh industrial environments.
Catalytic Combustion Sensors
These sensors operate by oxidizing flammable gases on a heated catalyst surface, producing a measurable change in resistance. They are cost-effective and widely used in gas detectors for methane, butane, and hydrogen. However, they require oxygen to function and degrade over time due to catalyst poisoning. The GDC series from Shanghai Gewe Electronic Safety Equipment Co., Ltd. uses anti-poison catalytic sensors with a lifespan exceeding 3 years, significantly improving reliability in petrochemical and mining applications.
Infrared (IR) and Laser-Based Sensors
Infrared sensors detect gases by measuring the absorption of IR light at specific wavelengths. They are highly selective, do not require oxygen, and are immune to poisoning. The GDE series detectors utilize high-performance IR/laser gas sensors with a lifespan greater than 5 years, offering ±3% measurement accuracy and minimal drift. These sensors are ideal for environments with high humidity, dust, or where long-term stability is critical, such as oil refineries and offshore platforms.
The GDE series also features automatic temperature compensation and zero-point calibration, ensuring consistent readings across -40°C to 70°C. With a T90 response time of 20–25 seconds and a color LED display visible from 25 meters, these detectors meet the demands of large-scale industrial facilities requiring remote monitoring.
Matching Sensor Type to Industrial Coverage Needs
Sensor selection must align with the physical layout and risk profile of the facility. For open or large-volume areas, IR-based detectors like those in the GDE and GDA series provide wide coverage due to their resistance to environmental interference. In confined spaces such as pipelines or storage tanks, electrochemical or PID sensors may be more appropriate for detecting low concentrations of toxic gases like H2S, CO, or VOCs.
The GDC series supports multiple sensor types—including catalytic, IR, and semiconductor—within a single platform, enabling flexible deployment across mixed hazard zones. Its modular design allows for pre-calibrated smart plug-in sensors, reducing downtime during maintenance. With IP66 protection and Exd IIC T6Gb explosion-proof rating, these detectors are certified for use in Zone 1 and Zone 2 hazardous areas.
Integration with IoT and Control Systems
Modern gas detection systems must integrate with centralized control platforms. The GM810/GM820 gas alarm controllers support RS485 and 4-20mA signal outputs, enabling seamless connection to SCADA systems and cloud-based monitoring. These controllers feature modular design, automatic addressing, and circuit protection technology, allowing rapid expansion without additional hardware.
Data from detectors can be transmitted via 4G or Wi-Fi modules to Gewe’s proprietary IoT cloud platform, enabling real-time alerts, historical trend analysis, and remote diagnostics. This integration supports predictive maintenance and compliance reporting, critical for facilities under strict regulatory oversight.
Environmental and Operational Considerations
Industrial environments often present challenges such as temperature extremes, high humidity, and mechanical vibration. The GDC series operates reliably from -40°C to 70°C with ≤95% RH (non-condensing), while the GDE series maintains performance with minimal zero drift (<2% per half-year). Both series use epoxy-coated or stainless steel enclosures for corrosion resistance in offshore or chemical processing applications.
For installations requiring remote operation, the GDA and GDE series support touchless infrared remote control, eliminating the need to open enclosures in hazardous areas. This feature enhances safety during calibration and configuration.
All detectors in the GDE, GDC, and GDA series comply with GB15322-2003, GB3836-2010, and are certified for fire safety (CCC), metrology (CPA), and explosion protection. They are engineered for high availability, with relay outputs capable of driving external alarms, shutdown systems, or ventilation controls.
In summary, effective gas detector sensor selection depends on matching technology to gas type, environmental conditions, and integration requirements. Shanghai Gewe Electronic Safety Equipment Co., Ltd. offers a comprehensive portfolio of detectors—backed by patented sensor intelligence, robust construction, and IoT connectivity—to ensure optimal coverage and safety in diverse industrial spaces.