Importance of Fixed Gas Detectors in Chemical Plants
Chemical plants handle hazardous substances that can release flammable and toxic gases. Fixed gas detectors monitor these environments continuously to prevent accidents. They detect gas leaks early, allowing for immediate response. In chemical processing, undetected leaks can lead to explosions or health risks for workers. According to industry standards, regular monitoring reduces incident rates by up to 70%. At Shanghai Gewei Electronic Safety Equipment Co., Ltd., we design detectors that integrate with plant safety systems for reliable operation.
Key Benefits for Safety and Compliance
Fixed gas detectors ensure compliance with regulations like OSHA and EPA standards. They provide real-time data logging for audits. Our systems support remote monitoring via IoT cloud platforms, enabling quick adjustments. This setup minimizes downtime and supports predictive maintenance. In chemical plants, detectors cover large areas, detecting gases such as methane, hydrogen sulfide, and carbon monoxide at low concentrations.
Types of Fixed Gas Detectors
Fixed gas detectors come in various configurations to suit chemical plant needs. Point detectors focus on specific locations, while open-path detectors monitor broader zones. We offer both in our product lineup, tailored for explosive atmospheres.
Catalytic Combustion Sensors
Catalytic combustion sensors detect combustible gases by measuring heat from oxidation on a catalyst surface. They respond quickly to methane and propane. Our GDC series uses imported catalytic elements with anti-poisoning technology, achieving a lifespan over three years. Precision is within ±5% FS, with response time T90 at 20-25 seconds. These sensors operate in DC24V systems, outputting 4-20mA signals for integration with controllers.
Infrared Gas Sensors
Infrared gas sensors absorb infrared light at specific wavelengths to detect hydrocarbons without oxygen dependency. They suit confined spaces in chemical plants. The GDE series employs high-performance infrared sensors with over five-year lifespan and ±3% precision. Features include automatic temperature compensation and zero-point calibration. Output modes include RS485 bus up to 1.5km, suitable for distributed monitoring.
Electrochemical Sensors
Electrochemical sensors generate current proportional to toxic gas concentration, ideal for detecting H2S or CO. They offer high selectivity. Our detectors incorporate these for precise toxic gas monitoring, with drift less than 2% per half-year. Integration with explosion-proof housings ensures use in Zone 1 and 2 areas.
Semiconductor and PID Sensors
Semiconductor sensors change resistance in gas presence, effective for VOCs. PID sensors ionize gases for ppb-level detection. The GDA series uses semiconductor types for cost-effective combustible gas monitoring, with compact design and IP66 protection. They fit in tight spaces like pharmaceutical areas.
Selecting the Right Detection Principle
Choose sensors based on target gases and environment. For flammables in oxygen-rich areas, use catalytic types from our GDC line. Infrared works in low-oxygen or poisoning-prone settings, as in GDE models. Electrochemical suits toxics. Consider factors like response time, accuracy, and maintenance needs. Our patented intelligent sensor technology allows plug-and-play modules, reducing installation time by 50%.
Environmental and Operational Factors
Chemical plants face high humidity, temperatures from -40°C to 70°C, and corrosive substances. Select detectors with epoxy-coated aluminum or stainless steel housings. Our products meet GB15322-2003 standards, with Exd IIC T6 Gb certification for hazardous zones. Preheating takes 3 minutes, with stable output in under 1 minute.
Installation and Integration
Install detectors at ground level for heavier gases or ceiling for lighter ones. Use bus or distributed wiring for scalability. Our GM810/GM820 controllers support modular expansion, automatic addressing, and multi-circuit protection. Connect via 4-20mA or RS485 to DCS systems. Integrate with our IoT cloud platform for 4G/WiFi remote access and mobile alerts.
System Components
A complete system includes detectors, controllers, and accessories like sound-light alarms and relay modules. The GM8 series handles up to hundreds of points, with touchscreen operation and stable communication. Pair with our flame detectors using UV/IR technology for comprehensive fire and gas protection.
Maintenance and Calibration
Regular calibration ensures accuracy. Our sensors support non-intrusive operation via remote controls, avoiding cover removal. Zero drift is under 2% semi-annually. Perform bump tests monthly and full calibrations yearly. The IoT platform logs data for trend analysis, predicting failures early.
Troubleshooting Common Issues
Check for signal faults indicated by 0-2mA output or LED status. Clean sensors from contaminants. Our designs include self-diagnostics for faults like sensor failure at 2-2.5mA. Relay outputs trigger alarms at 2A capacity.
Compliance and Standards
Adhere to GB3836-2010 and international IECEx standards. Our products hold CCC fire approval and CPA metering licenses. Fixed detectors aid in HAZOP studies and risk assessments. Integrate with emergency shutdown systems for full compliance.
In summary, deploying robust fixed gas detectors like our GDE, GDC, and GDA series enhances safety in chemical plants. With IoT integration and advanced sensors, these systems ensure operational efficiency and regulatory adherence. Contact us for customized solutions.