Is the damage of gas detectors due to poor quality? A full analysis of the underlying reasons! In the safety system of industrial production, gas detectors are indispensable “guardians”. They continuously monitor the gas concentration in the environment. Once it is found to exceed the standard, it will immediately warn and build a defense line to prevent danger. However, in actual applications, when the gas detector fails or is damaged, many users will subconsciously think that the product quality is not up to standard. Is the gas detector really so “delicate”? Let us unveil the mystery of the “failure” of the instrument.
“Invisible attack” of the external natural environment
The gas detector is in a complex environment for a long time, and the continuous interference of external natural factors is the main cause of its failure.
Continuously high ambient temperature will cause the performance of the electronic components inside the detector to decay and accelerate aging, and even cause thermal breakdown in severe cases;
The low temperature environment may reduce the sensitivity of the sensor, and also cause cracks in some components due to low temperature embrittlement.
In high-temperature places such as metallurgical workshops, if the sensor of the combustible gas detector is above the upper limit of the tolerance temperature for a long time, its service life will be greatly reduced.
High humidity environment can easily cause moisture inside the detector, which in turn causes problems such as circuit short circuit and corrosion of metal parts. Especially when the humidity reaches the dew point, it will directly damage the electrical performance of the instrument and cause irreversible damage.
For example, in aquatic processing workshops or underground humid warehouses, combustible gas detectors often malfunction due to humidity problems.
If there are corrosive gases, liquids or dust around, they will react chemically with the sensitive elements and shell of the detector, gradually disintegrate the structural integrity of the instrument, and cause performance failure.
In chlor-alkali chemical enterprises, trace leakage of corrosive gases such as chlorine will cause continuous corrosion to the probe of the gas detector and shorten its service life.
Severe fluctuations in air pressure, excessive wind speed, and strong electromagnetic radiation may cause zero drift in the detector, that is, non-zero concentration is displayed when there is no target gas, which will directly affect the credibility of the detection data.
“Natural loss” of internal components
The sensors, circuit boards and other components inside the detector have a fixed service life. As the use time accumulates, their sensitivity will gradually decrease, and eventually they will be “retired” due to substandard performance. Usually, the effective service life of gas detectors is 3-5 years. After this period, they need to be replaced in time to ensure detection accuracy.
If there are problems such as component cold soldering and the selection of inferior materials during the production process, the instrument will frequently fail in the early stage of use, which is a typical quality defect.
“Impact effect” of the gas itself
When the detector suddenly contacts a high-concentration gas that far exceeds the range, the sensitive component may fail permanently due to “overload”. At the gas pipeline emergency repair site, if the detector is directly exposed to the leaking high-concentration natural gas, it is likely to lose its detection ability instantly.
Impurities such as dust and oil mist in the measured gas will block the detector’s air intake channel or adhere to the surface of the sensitive element, hindering the contact between the gas and the sensor, resulting in detection failure. In the paint shop, paint mist particles will contaminate the probe of the combustible gas detector, causing it to falsely report or not report.
“Human factors” in installation and use
If the detector is installed in a ventilation dead corner, directly above the heat source or near a strong electromagnetic field (such as next to a transformer), it will accelerate the aging of the instrument and affect the detection accuracy. Gas detectors installed next to the motor control cabinet often have data jumps due to electromagnetic interference.
Long-term lack of cleaning, calibration and functional testing will cause dust accumulation, zero offset and other problems to gradually worsen, eventually causing instrument damage. For example, in a dusty workshop, if the detector probe is not cleaned for half a year, the detection sensitivity will be greatly reduced due to dust coverage.
How to effectively extend the life of the gas detector?
Installation specifications
– Determine the installation height according to the specific gravity of the gas: for detecting gases lighter than air (such as natural gas), install it 0.3-0.6 meters from the ceiling; for detecting gases heavier than air (such as liquefied petroleum gas), install it 0.3-0.6 meters from the ground.
– Avoid heat sources, strong electromagnetic sources and areas where people frequently touch, and ensure that the installation is firm and vibration-proof.
Key points for use
– Strictly follow the operating manual for power on, power off, calibration and other operations to avoid illegal operations.
– Regularly check the appearance and alarm function, and immediately stop and repair if abnormalities are found.
Maintenance measures
– Regularly calibrate to ensure detection accuracy.
– Clean the probe surface with a soft brush regularly, and avoid using corrosive cleaning agents such as alcohol.
– Replace core components such as sensors in time when they expire, and do not exceed the service life.
Gas detector damage is the result of multiple factors, of which quality issues are only a part. Through scientific installation, standardized use and regular maintenance, its reliability can be greatly improved, allowing this safety “sentinel” to continue to play a role and safeguard industrial production.
