Gas detectors are core equipment for monitoring flammable and toxic gas leaks. Their effective operation is directly related to the production environment and personnel safety. To achieve scientific management of gas detectors, a comprehensive management system must be established, from initial planning and parameter setting to daily monitoring, emergency response, and regular maintenance. This process can be divided into the following five key steps:
Before installing gas detectors, an assessment team composed of professionals from various fields, including process, equipment, instrumentation, and safety, should be assembled. A comprehensive risk analysis should be conducted in collaboration with the design firm. First, the types and characteristics of flammable and toxic gases involved in the production process should be identified. Then, key areas of potential leaks should be precisely located. This includes the dynamic seals of gas compressors and liquid pumps, liquid (gas) sampling ports, drain (water) ports, and vent ports, as well as frequently disassembled flanges and frequently operated valve blocks. The gas diffusion patterns and potential risks in these areas should be analyzed. Through systematic analysis, determine the installation location, quantity, and type of detectors to avoid issues like “should be installed but not installed” or “mismatched types,” ensuring accurate coverage of risk areas.
How can gas detection be scientifically and effectively managed?
For toxic gas detectors, at least two alarm thresholds should be set based on the toxicity level of the gas and safety standards. Different alarm levels should be clearly distinguishable (e.g., different frequencies of sound and light, different colored indicators) to facilitate quick identification of risk levels. The first-level alarm (low threshold) can be set as a warning, prompting on-site personnel to increase inspections; the second-level alarm (high threshold) should be set as an emergency warning, triggering subsequent emergency response procedures. Alarm value settings should be based on industry standards and actual operating conditions to avoid missed alerts due to excessively high thresholds or false alarms due to excessively low thresholds. This ensures that alarm signals accurately reflect risks while allowing sufficient time for response.
How can gas detection be scientifically and effectively managed?
Establish a comprehensive gas detector management record, detailing detector model, installation location, range, alarm threshold, calibration cycle, maintenance history, and other information. Verify each record against the plant floor plan. Draw a distribution map of flammable and toxic gas detector detection points throughout the plant and at each facility to facilitate daily management and rapid location of alarms.
The fire control room must prioritize monitoring of two types of signals: secondary flammable gas alarms and fault signals from the alarm control unit. Leaving the monitoring system “shelved” is strictly prohibited. Furthermore, dual audible and visual alarms must be installed in both the control room operating area and on-site alarms. Given the potential for noise interference in the production environment, a combined audible and visual alarm system effectively eliminates the “inaudible, invisible” problem. Furthermore, staff are strictly prohibited from arbitrarily disabling alarms under the pretext of “frequent alarms.” A “first-responsibility” system for alarm system management must be established, clearly identifying the primary responsible person to ensure prompt detection and rapid response.
How can gas detection be scientifically and effectively managed for safety?
Regularly organize staff training on gas detector alarm handling, clarifying the handling procedures for different types of alarms (such as combustible gas alarms, toxic gas alarms, and equipment failure alarms). Standardize the “Combustible and Toxic Gas Alarm Record,” which should include the alarm time, location, gas type, alarm level, handling personnel, handling measures, and results.
When receiving a gas detection system (GDS) alarm, a strict “locate – record – notify – verify” process must be followed: First, control room personnel quickly identify the alarm instrument’s location and location through the system; second, immediately record the alarm information to avoid missing critical information; third, immediately notify on-site inspection personnel or the emergency response team, who will visit the alarm point to verify the cause of the alarm (e.g., whether there is a gas leak, detector malfunction, etc.); fourth, implement appropriate measures based on the verification results. If a leak is confirmed, immediately activate the emergency response plan; if a detector malfunction is detected, arrange for prompt repair. Standardizing the handling process can avoid delays or errors caused by panic.
How can gas detection be scientifically and effectively managed for safety?
As precision instruments, gas detectors require regular maintenance and calibration to ensure stable performance. Specifically, three tasks must be performed:
Daily maintenance and root cause investigation: After each alarm, thoroughly investigate the root cause. Common causes include: gas leaks in the measured environment, improper alarm threshold settings, uncalibrated detectors, sensor damage, and equipment wiring faults. Appropriate measures should be taken for each cause (e.g., leaks should be repaired, thresholds adjusted, or sensors replaced).
Regular calibration: Detection and alarm devices should be calibrated in accordance with the “Combustible Gas Detector Alarm” (JJG 693-2011), generally no more than once a year, to prevent sensor problems and zero drift. If the instrument is subjected to severe vibration or impact, or if a critical component is replaced or repaired, it should be calibrated promptly. If the detection and alarm device fails calibration or is found to be faulty, it should be repaired or replaced immediately.
Timely calibration in special circumstances: If a detector is subjected to severe vibration or impact, or if core components (such as sensors or circuit boards) are replaced or repaired, calibration must be performed immediately, rather than waiting for the regular calibration cycle. If the device fails calibration or is faulty during calibration, it must be shut down immediately for repair or replacement. The device can only be put back into service after it has returned to normal operation.
How can gas detectors be scientifically and effectively managed for safety?
Gas detectors are the “sentinels” that safeguard gas environment safety. The quality of their management directly determines the effectiveness of their safety protection. During equipment installation, parameter setting, daily monitoring, emergency response, and maintenance and calibration, personnel must strictly adhere to industry standards and management procedures, responding quickly to warning signals and effectively handling them. This ensures “preventive measures” and builds a solid defense for production safety.
