Toxic, Flammable, and Explosive Gas Detector Survey
Many factories use hazardous, toxic, and/or flammable gases in various production processes.
The use of hazardous gases necessitates the implementation of robust safety infrastructures to monitor airborne gases within the facility. This is essential not only to prevent leaks or detect them promptly but also to protect employees, the environment, and the facility itself.
As a condition of the hazardous materials (Poison) permit, such factories are required to install appropriate safety and protective equipment for gas handling, conduct a dedicated detector survey to assess the adequacy of existing systems, and develop a plan to address any identified gaps.
Recently, requirements for detector surveys in facilities handling hazardous gases have expanded and now cover plants classified as type A and, in some cases, type B.
The requirement for a gas detector survey is clearly stipulated in the hazardous materials permit conditions and must be completed within one year of obtaining or renewing the permit.
In practice, most facilities dealing with hazardous gases that have not yet conducted such a survey, or have undergone significant changes in their production process, will likely encounter this requirement either as part of the renewal process for their hazardous materials permit or following supervisory inspections.
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Gas Detection Systems
Gas detection systems consist of detectors or sensors strategically placed within the facility, designed to detect, identify, and monitor hazardous gas leaks in the air.
Detectors are installed at various critical points (such as pipeline connections or near gas-operated systems), acting as an early warning system by detecting rising concentrations of hazardous gases in the facility air.
In the event of a leak, digital control units receive signals from the detectors and trigger alerts. In some cases, these controls are connected to systems that cut off power, automatically close valves, and activate other safety measures.
Sutok’s environmental engineering consultants highlight the importance of conducting detector surveys for compliance purposes and draw on their extensive experience in the field.
What Is a Gas Detector Survey?
A gas detector survey is designed to assess the need for detectors, their proper placement, and the suitability of the existing detection array to regulatory requirements.
The survey evaluates, among other points:
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Are the location and type of detectors appropriate for the specific properties of the gas in use?
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Are the number of detectors suitable for the plant's operations?
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Are the defined alarm thresholds appropriate?
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Do the detectors comply with the required standards?
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What is the necessary calibration method and frequency?
The process involves mapping operational processes by exposure and usage of hazardous gases and creating a gap-closing plan including recommendations for additional detectors and proper calibration.
This plan will:
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List all current detectors (if any) and state whether they comply with standards.
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Recommend replacement where detectors do not meet requirements.
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Identify needs for additional detectors or other safety measures if any are missing.
To prevent gas leaks, various types of sensors are used, such as hydrogen detectors, LPG detectors, carbon monoxide detectors, carbon dioxide detectors, and more, reflecting the wide range of toxic or flammable industrial gases.
Optimizing detector placement and matching the detector to the specific gas involved are critical for effective leak prevention.
Legal Requirement and Safety Component
A gas detector survey is not only a legal requirement: it is also a key element of a comprehensive safety risk assessment, helping you manage hazardous gases safely and avoid risks to staff, your facility, and the environment.
The Importance of Conducting a Detector Survey
SUTOK’s experts emphasize the significant safety and financial benefits of carrying out detector surveys. For example, in a recent project for a factory in southern Israel that consumes large amounts of gas in production, a professional survey was conducted. The facility included numerous welding stations connected to a central gas line. During the survey period, the plant switched from an environmentally harmful refrigerant gas to a significantly more flammable, yet eco-friendlier, alternative.
The lead consultant explained:
“Our work involved mapping all gas-using stations and evaluating the suitability of the existing detectors and controllers. We then developed a gap-closure program according to the new guidelines from the Ministry of Environmental Protection. The final delivery provided the client with a comprehensive document containing our detailed recommendations. This required interdisciplinary expertise in both environmental regulation and relevant safety standards.
“Performing the survey professionally- by Sutok, who have no commercial interest in selling detectors- allowed the plant to save thousands of shekels. In many cases, compliant detectors were already in place and did not require replacement, which constitutes a real success in our eyes.”
Sutok – Environmental Engineering Consultants
Sutok specializes in providing professional environmental engineering consultancy, supporting factories and companies in overcoming environmental challenges through research, analysis, and the integration of advanced technological solutions, as well as by fostering partnerships and collaborations.
Our consultants are experts in conducting gas detector surveys, regulatory guidance, and assisting industrial facilities in obtaining hazardous materials permits, while also providing effective solutions for environmental issues, resource savings, and optimizing production processes.
If you are an owner or manager of an industrial facility using hazardous gases, it is crucial to be aware of your regulatory obligations.
Contact us today for expert advice and professional support regarding gas detector surveys and additional environmental solutions.