gas risk management sierra monitor and rep firm welcome: abc engineering
TRANSCRIPT
Gas Risk ManagementGas Risk Management
Sierra Monitor and Rep Firm Welcome:
ABC Engineering
Gas Risk ManagementGas Risk Management
Introduction
Gas Risk Management
Was this caused by someone not paying attention?
Gas Risk Management
Did some piece of equipment or instrumentation fail?
Gas Risk Management
Did someone not follow procedure?
Gas Risk Management
Could a properly functioning safety system have prevented the disaster?
Gas Risk Management
• Explanation of hazardous gases
• Characteristics of common toxic gases
• Sensor Technology
• Portable and Fixed systems
• Placement of fixed sensors
• Elements of risk reduction
• Overview of available equipment
• Resources and reference
• Applications and usage
Gas Risk ManagementGas Risk Management
Hazardous Gases
Hazardous Gases
• Combustible Gases– Explosion or fire hazard– Must maintain concentration below lower explosive limit (LEL)
• Toxic Gases– Hazardous to human health and safety– Employee exposure must be limited
• Oxygen Displacing Gases– Indirect human health hazard– Deficiency of breathing Oxygen
Combustible Gases
• Lower Explosive Limit (LEL)– Also Lower Flammable Limit (LFL)
– What does it mean?
– % Volume vs. % LEL
• ASTM E681 Standard– Benchmark test to determine LEL
– Tested in Air with 20.9 % Oxygen
Combustible Gases
Too Rich forCombustion
Will SupportCombustion
Too Lean forCombustion
Upper Explosive LimitU.E.L.
Lower Explosive Limit100 % L.E.L.
100%
0%
CO
NC
EN
TR
AT
ION
(% G
as in
Air
)100% LEL Methane = 5% by volume
Combustible GasesC
ON
CE
NT
RA
TIO
N(%
Gas
in A
ir)
100%
0%5%
15%
0%100% LELUEL
Methane
CO
NC
EN
TR
AT
ION
(% G
as in
Air
)
100%
1.5%7.8%
100% LELUEL
PentaneThe flammability
of many gases lies in a very limited range
The LEL differs depending upon the type of gas
Combustible Gases
Combustion Requires• Fuel Source
• Oxygen or Air
• Ignition Source
Combustible Gases
• Possible Ignition Sources– Static Electricity Discharge– Open Flames– Hot Surfaces– Mechanical Friction– Electrical Arc or Spark– Two Way Radio Transmitter– Tools and Test Equipment
Toxic GasesHazard to Human Health and Life Safety
PPM = Parts Per Million
• 1% by volume = 10,000 ppm
• 1 ppm = .0001% by volume
• 1 millionth of the width of the U.S. is 12 feet
Toxic Gases
• Permissible Exposure Limit (PEL)– Time Weighted Average (TWA)
– Short Term Exposure Limit (STEL)
• Immediate Danger to Life and Health (IDLH)
• Relative Gas Density– RGasD Air = 1.0
– Lighter than air, Below 1.0
– Heavier than air, Above 1.0
Carbon Monoxide HazardConc. of CO in Air Toxic Symptoms
100 ppm Fatigue and feeling of being tired
400 ppm Headache within 1-2 hrs., widespread in 2.5 - 3.5 hrs.
500 ppm Dizziness, nausea, convulsions within 45 min.
1,600 ppm Headache, dizziness, nausea within 20 min. Death in 2 hours.
3,200 ppm Headache, nausea within 5-10 min. Death within 30 min.
6,400 ppm Headache, dizziness within 1-2 min. Death within 10-15 min.
12,800 ppm Death within 1-3 minutes.
Carbon Monoxide Hazard
• OSHA General Industrial Safety Order for Carbon Monoxide– Permissible Exposure Limit
(Max. 8 hr. TWA) = 50 ppm
– Short Term Excursion Limit (STEL) = 200 ppm for 15 min/8 hrs
– IDLH = 1200 ppm
– RGasD = 0.97
Chlorine HazardConc. of Cl2 in Air Toxic Symptoms
0.1 ppm Minimum concentration detectable by odor3 ppm Difficulty breathing eye and throat irritation10 ppm Causes serious throat irritation, smarting of eyes30 ppm Coughing, more severe throat irritation, general feeling of
discomfort in the chest40 ppm Respiratory reflexes, coughing, burning of eyes, nausea,
vomiting. Possible death within 30 minutes100 ppm Death within a few breaths
Uses: Water purification, sanitation of industrial wastes, swimming pools, bleaching of pulp and textiles, manufacture of various chemical compounds
Chlorine Hazard
• OSHA General Industrial Safety Order for Chlorine– Permissible Exposure Limit
(Max. 8 hr. TWA) = 0.5 ppm
– Short Term Excursion Limit (STEL) =1 ppm for 15 min/8 hrs
– IDLH = 10 ppm
– RGasD = 2.47
Hydrogen Sulfide HazardConc. of H2S in Air Toxic Symptoms
1 ppm Odor detected, irritation of respiratory tract
10 ppm Allowable for 8 hours exposure (OSHA)
20 ppm Protective equipment is necessary
100 ppm Smell killed in 5 to 15 minutes. May burn
eyes and throat; coughing
500 ppm Respiratory disturbances in 2 to 15 minutes.Coughing, collapse & unconsciousness
1,000 ppm Immediate unconsciousness. Brain damage may result unless rescued promptly. Death in 3 to 5 minutes.
Hydrogen Sulfide Hazard
• OSHA General Industrial Safety Order for Hydrogen Sulfide– Permissible Exposure Limit
(Max. 8 hr. TWA) = 10 ppm– Short Term Excursion Limit (STEL) = 15 ppm for 10 min/8 hrs
– IDLH = 100 ppm
– RGasD = 1.19
Ammonia HazardConc. of NH3 in Air Toxic Symptoms
2 ppm First perceptible odor40 ppm Slight eye and throat irritation100 ppm Acute Irritation of eyes and nasal passages400 ppm Severe irritation of throat, nose, upper respiratory tract700 ppm Severe eye irritation1700 ppm Serious coughing, bronchial spasms, death within 30 min.5000 ppm Serious edema, strangulation, asphyxia, death immediate
Uses: Refrigerant gas, used in soil fertilization, ammoniate fertilizers. Used in metal treating and for extraction of metals from ores. Used as a neutralizing agent of acids in oil and in the manufacture of various chemical compounds. Also used to purify municipal water supplies.
Ammonia Hazard
• OSHA General Industrial Safety Order for Ammonia– Permissible Exposure Limit
(Max. 8 hr. TWA) = 25 ppm
– Short Term Excursion Limit (STEL) = 35 ppm for 15 min/8 hrs
– IDLH = 300 ppm
– RGasD = 0.60
Oxygen Deficiency HazardOxygen Content Symptoms Developed
20.9% Normal Oxygen concentration in air
15 - 19% Decreased ability to work strenuously.
May impair coordination
12 - 14% Respiration increases in exertion, pulse up, impaired coordination, perception & judgment
8 - 10% Mental failure, fainting, unconsciousness, blueness of lips, nausea & vomiting
6 - 8% 8 minutes, 100% fatal; 6 minutes, 50% fatal,
4 - 5 minutes, recovery with treatment
4 - 6% Coma in 40 seconds, convulsions, respiration ceases, death
Oxygen Deficiency Hazard
• Industry Guidelines for Oxygen Deficiency– Breathing gear required below 19.5% and above
23.5% Oxygen content in air
– Confined Space permit procedures may need be followed in some areas
Gas Risk ManagementGas Risk Management
Gas Sensor Technology
Sensor Technology
• Catalytic Bead
• Infrared
• Electrochemical
• Semiconductor
Catalytic Bead
• No Temperature or Humidity Effect
• Silicone and Sulfide Resistant
• 0-100% L.E.L. Scale
• Responds to All Combustible Gases
• Wheatstone Bridge
Catalytic BeadWheatstone Bridge
DCSupply
Output
Detector
Compensator
Infrared
• Methane or Propane• Carbon Dioxide• Accurate & Stable• Large Measurement
Range• Low Maintenance
Sample Cell
Detector Source
Electrochemical• Current Generating
Electrolytic Reaction
• High sensitivity for PPM levels of Toxic Gas
• Specificity to Gas of Interest
• Percent Volume for Oxygen Measurement
Electrolyte
Diffusion Point
Electrodes
Semiconductor (Solid State)
• Long Life Sensor
• Semiconductor Resistive Film
• PPM Range
• High Sensitivity
• Poor Selectivity
• Non-Linear Response
Nobel Metal WireSensor
Heater Coil
Detection Techniques
Combustible Catalytic bead, Semiconductor, Infrared
Oxygen Electrochemical
Toxic Gases Semiconductor, Electrochemical, Infrared
Gas Risk Management
• Explanation of hazardous gases
• Characteristics of common toxic gases
• Sensor Technology
• Portable and Fixed systems
• Placement of fixed sensors
• Elements of risk reduction
• Overview of available equipment
• Resources and reference
• Applications and usage
Portables vs. Fixed
• Use Portables– When area is not normally occupied– When area has no power or infrastructure– When temporary work crew must maintain their own safety
equipment– When fixed system is down for maintenance
• Use of Fixed Systems– When area is regularly occupied– When automatic systems must react to a hazardous gas
condition – When insurance or regulatory issues require it– When risk assessment concludes that area must be monitored
continuously 24/7
Portable Devices• Battery Powered
• Can be moved from area to area
• Monitor is attached to the individual who is performing the work
• Prone to damage
• Should be calibrated before every use
Permanent Fixed Installations
SCADA
Calibration & Validation• Factory Mutual (FM) requires that
all approved sensors be calibrated periodically
• Sensor must be exposed to live gas standard to validate performance
• Regular calibration compensates for environmental changes
• Records must be maintained to meet OSHA Due Diligence requirements
• Calibration gas must be certified as primary gas standard
Gas Risk ManagementGas Risk Management
Gas Sensor Placement
Gas Sensor Placement
• Use engineering judgement
• Consider:– Probability of gas leak
– Quantity of gas that could leak
– Environmental conditions
– Dilution rates and convection currents
– Density of gas
– Interfering gases
Gas Sensor Placement
• Place sensors close to possible gas source
• Place sensors in areas where gas might accumulate
• Place toxic gas and oxygen deficiency sensors in the “breathing zone”
• Consider accessibility and maintenance issues
Gas Weight in Relation to Air
• Ammonia Lighter• Butane Heavier• Carbon Dioxide Heavier• Carbon Monoxide Slightly Lighter• Methane Lighter• Chlorine Heavier• Ethane Slightly Heavier• Ethylene Slightly Lighter• Heptane Heavier• Hydrogen Lighter
Gas Weight in Relation to Air
• Hydrogen Chloride Heavier• Hydrogen Cyanide Lighter• Hydrogen Sulfide Heavier• Methyl Alcohol Heavier• Nitric Oxide Slightly Heavier• Nitrogen Dioxide Heavier• Pentane Heavier• Propane Heavier• Sulfur Dioxide Heavier• Toluene Heavier
Gas Risk ManagementGas Risk Management
Risk Reduction
Responsible Risk Management
• Identify hazards...
• Assess risk of hazardous event...
• Comply with laws, insurance requirements...
• Consider liability, financial risks...
Develop and implement a strategy of comprehensive event response and prudent risk management
Risk Reduction
InsuranceRequirements
CompanyPhilosophyRisk to
Personnel
Risk toEnvironment
Risk toFacility
Hazard Identification &Assessment
Control SystemCapability/Cost
Tradeoffs
Laws &Regulations
Decision,Control Strategy,System Selection
FinancialRisks
Liability
Risk Reduction
Proper Equipment Selection
• Portable systems– Minimal risk of hazardous event– Battery powered, must be carried on person
• Gas Alarm Monitors– Minimal risk of hazardous event– Simple alarm alert, relay output
• Analog Monitors– Moderate risk in defined location– Continuous display, warning and high alarms, limited
diagnostics
Proper Equipment Selection
Gas Alarm Monitors/Systems
Analog Monitors (Single Point)
Distributed Digital Systems (Multi-Point)
Multi-Point Systems
Single Point SystemsGas Alarm Systems
Proper Equipment Selection
Risk Management Systems– Constant risk of hazardous event, defined areas or
facility-wide
– Distributed intelligence for local control and remote monitoring
– Comprehensive event response
– Configurable alarm logic
– Extensive calibration, diagnostic capabilities
– Documentation of due diligence
Sentry - Basic Configuration
110 VACor
220 VAC
12 - 28 VDC
Low Alarm
High Alarm
Trouble
RS232 SerialOutput to
Printer
Resources & Reference
• ANSI/NFPA #325 Guide to fire hazard properties of flammable liquids, gases and volatile solids
• ANSI/NFPA #820 Fire protection in wastewater treatment and collection facilities
• NIOSH Guide to chemical hazards
• OSHA Guide for confined space hazards
Markets - Gas Detection
• Water/Wastewater Treatment Plants
• Chemical/Petrochemical Plants
• Landfills & Solid Waste
• Alternate Fueled Vehicles
• Food & Drug
• Parking Garages
• Gas/Oil Operations
• Pulp & Paper
Water/Wastewater Treatment• Pumping Stations
– Combustible gases, H2S, O2
• Influent/Barscreen Rooms– Combustible gas, O2
• Grit Chamber & Wet Wells– Combustibles, O2, H2S
• Digester– Combustible gas, HCombustible gas, H22SS
• Furnace Room– Combustible gas, COCombustible gas, CO
• Disinfection/ Dechlorination– ClCl22, SO, SO22, NH, NH33
Chemical/Petrochemical Plants• Pipelines & compressor
stations– Combustible gas, H2S, flame
• Laboratories– Toxic gases, O2 deficiency
• Railroad/truck loading stations– Combustibles, toxics, flame
• Storage tanks– Combustibles, flame
Gas/Oil Operations• Well site perimeters
– Combustible gas, H2S
• Sweetening plants, sour gas wells — H2S
• Pipelines & compressor stations– Combustibles, toxics, flame
• Drilling operations– Combustible gas, H2S, oxygen
deficiency, flame
• Combustible gas leaks
Remote Site Monitoring
• Modbus RTU serial communication link from Sentry interfaces to a FieldServer WebServer
• WebServer uses Sentry data to build dynamic browser pages
• Browser pages may be viewed over LAN, WAN or Internet
RS-232Modbus
Sentry Digital Bus Ethernet
I nternet
Sentry WebServer• The Main screen ranges from the default layout of a
single Sentry system to custom graphics that can include a photo or drawing of the building with buttons to specific zones
Default Custom
Review & Discussion
Sierra Monitor Corporationwww.sierramonitor.com
800-72-SIERRA
800-727-4377
FieldServer Technologieswww.fieldserver.com
888 509-1970