Integrating flame detection into safety systems can create a safer and more reliable environment. (Image source: MSA Safety)

MSA Safety discusses the benefits of a layered defense incorporating both gas and flame detection for safety in industrial environments

In industrial settings, safety is paramount, especially in environments where flammable or toxic gases are present, such as the oil, gas and petrochemical industry.

A robust gas detection system is an important line of defense, but it is not the whole story. Integrating flame detection into your safety setup can create a safer and more reliable environment.

The role of gas and flame detection systems

Gas detection systems are designed to identify harmful gases in the air, whether combustible, toxic, or asphyxiating. They provide early warnings, helping to enable preventive action before conditions become dangerous. However, gas detection alone doesn’t account for what happens when a gas leak ignites.

Flame detection systems complement gas detectors by identifying the presence of fire, which may occur even where gas concentration hasn’t yet reached detectable levels. Together, these systems can contribute to a more comprehensive safety net that addresses both potential and actual hazards.

Why include flame detection in gas detection systems?

1. More comprehensive hazard mitigation

Gas detectors and flame detectors work hand-in-hand to prevent accidents and mitigate risks. While gas detectors alert you to the presence of a leak, flame detectors respond to fires that could result from undetected or ignited gases.

2. Faster response to fire emergencies

A gas leak can ignite in seconds, turning a potential hazard into an active emergency. Flame detectors react in real-time to the presence of a flame, helping to enable prompt action to contain the fire and prevent escalation.

3. Helps eliminate blind spots

Gas detection systems can only monitor specific zones. In scenarios where a leak occurs outside the detection range or a minor leak ignites directly, flame detectors can be an important second layer of protection.

4. Tailored for high-risk industries

In industries such as oil and gas, petrochemicals and manufacturing, the risk of fire due to flammable gases is ever present. Flame detection helps protect these high-stakes environments against both minor and catastrophic ignition events.

5. Meeting regulatory standards

Safety regulations often require both gas and flame detection systems for compliance. Adhering to these standards not only protects your team and assets but also ensures your operations meet legal and industry benchmarks.

6. Minimising damage and downtime

Early flame detection can activate suppression systems, limit the spread of fire, and enhance the safety of personnel. By containing incidents quickly, businesses can avoid costly equipment damage and extended downtime.

7. Enhanced operational safety and continuity

Combining gas and flame detection creates a more resilient safety framework that reduces the likelihood of accidents and enables a quicker recovery in the event of an incident. This reliability is key to maintaining trust and productivity.

A layered defense

Safety in industrial environments is not about choosing between gas or flame detection — it’s about understanding the benefits of both to build a layered defense.

While gas detectors prevent potential hazards by identifying leaks, flame detectors act as a safeguard when ignition occurs.

Safety managers may consider this combination a necessity in today’s high risk, high stakes industries. By integrating flame detection into your gas detection system, you help to ensure that your operations are protected from the full spectrum of potential hazards, safeguarding lives, assets, and your reputation.

Figure1: The importance of 'when' versus 'what' in decision making. (Image source: SafeStart)

Figure 1

Larry Wilson, author and CEO, SafeStart, reviews the lessons of the ‘complacency continuum’

As we revisit the Paradigm Shifts series, we are now approaching its final stretch with article #9 out of 12: Critical Decisions – Part 1: Normal Risk vs. Making an Exception.

Before diving in, let’s briefly recall the key insights from the previous article, where we explored the complacency continuum and the importance of 'when' vs. 'what' in decision-making (Please see Figure 1).

When did you get hurt vs. what were you doing? And if you really think about it or if you really think about what has actually happened to you, you’ll realise that you have most likely experienced accidental pain – even if it wasn’t serious – in almost any activity you’ve ever done, whether it’s walking, running, cleaning, carrying something and dropping it on your foot, cutting, hammering, driving, cooking, sewing (you name it), chances are you’ve said, “Ouch” or something worse, more than once. So, if you can accept that the “what” isn’t really where the pattern is, because, we’ve all been hurt, a little or a lot, doing pretty much everything (as long as you were moving and/or things around you were moving). So, the pattern, especially in terms of our serious injuries, has been when we made both of the first two critical errors at the same time: we didn’t have our eyes on task and we weren’t thinking about what we were doing (mind not on task). And as a result, we didn’t get a reflex – which might have enabled us to hit the brake, jerk the steering wheel, catch our balance or break our fall, move our head quickly, etc.

So, we looked at the problem of figuring out “when” in the last article. When would we or when would they be most likely to have those “defenseless moments”? The conclusion was that they (at least the majority of them) would happen after the first stage of complacency, and – although the person wouldn’t likely know it – be happening more frequently as they passed into stage 2. Which helped to answer the question of why older, well-trained workers, with lots of experience were experiencing so many serious injuries and fatalities. Note: before the first stage of complacency, untrained workers or workers without enough experience do get hurt frequently. But they are usually more mindful in terms of paying attention. They just don’t have the skills or reflexes yet. So, that’s easy to understand and it’s easy enough to fix, if you’re willing to take the time to train them properly.

However, there’s more to it than just that. As mentioned, albeit briefly, in the last article, as time goes on people tend to get more complacent, not less. The increased level of complacency can also start to affect someone’s decision making. Not only do they have more “defenseless moments”, but if nothing bad has actually happened (vs. just another close call) then the person’s willingness to change will be very low, and certainly their belief that their behaviour “really needs to change” will be virtually non-existent. Hence the: “Oh yeah, well I’ve been doing it this way for 20 years and I’ve never been hurt yet!” So, for them, “normal” behaviour is “at-risk”. In other words, they normally don’t wear the face shield at the grinding wheel or they normally don’t wear a seat belt on the fork truck. And if someone has been using the grinding wheel without a face shield for 20 years, we can assume – with a fair bit of confidence – that complacency has gotten the better of them.

Then on the other side (see Figure 1), there are people whose normal behaviour is safe: they normally do wear the face shield. Just like people normally drive the speed limit or maybe a little above the posted speed limit. In other words, you know what you mean when you say, “I was driving at normal speed or at a normal speed for me, given the conditions”. Let’s just call it, “our own speed limit” which, as mentioned, might be slightly higher than the posted speed limit. But here’s the thing or the main point: we have all exceeded our own speed limit when we were in a “big rush”. So, if we are in enough of a rush, we will make an exception, and not only break government laws or company rules, we will even break our own rules. And the same thing can be true for frustration and fatigue. Normal people can and will make exceptions or can have their decisions compromised by rushing, frustration and fatigue.

I can remember when this paradigm shift hit me. I was in Houston doing a three-day workshop. Our video crew lives in the greater Houston area, so we got together after day one to look at some of the “Tool Box” videos for a series they started working on. Although the manager of the crew was very familiar with the concepts and critical error reduction techniques, the crew really only knew about rushing, frustration, fatigue and complacency. What I didn’t know (long story) was that the manager was not going with the crew to these shoots, so they were just asking for stories – true stories – that were about workplace injuries caused by rushing, frustration, fatigue and complacency.

Click here to read the full article and gain insights into enhancing safety through improved decision-making.

Stay tuned for Critical Decisions – Part 2: Deliberate Risk and Error, where we dive deeper into how intentional risk-taking interacts with human error and what we can do to mitigate it!
https://uk.safestart.com/paradigm-shifts/9-critical-decisions-part-1-normal-risk-vs-making-an-exception/

The Teledyne GFD Spyglass Xtend triple-infrared flame detector. (Image source: Teledyne GFD)

Teledyne Gas & Flame Detection (Teledyne GFD) has released its Spyglass Xtend triple-infrared flame detector, for the simultaneous detection of both hydrogen (H2) and hydrocarbon (HC) fires

Given that an H2 detector cannot detect HC flames, Teledyne GFD's innovation enhances safety in dense industrial environments where hydrogen flames can spread to other equipment and start fires involving hydrocarbon fuels that are invisible to an H2-only detector. With its integral triple-infrared technology and a unique algorithm, the new Spyglass Xtend flame detector detects both hydrogen and hydrocarbon flames simultaneously, providing greater worker and asset protection. Five selectable sensitivity levels are available.

Eliminating false alarms

The new triple-infrared technology eliminates false alarms or untimely faults due to sun glare or heavy rain, guaranteeing reliable operation in outdoor environments. The detector also features heated optics, preventing condensation and frosting, and automatic or manual self-tests that check the optics are clean. The stainless steel enclosure carries IP66/68 and NEMA 4X/6 ingress protection ratings.

Teledyne Gas and Flame Detection’s Spyglass Xtend offers a number of universal current outputs, including analogue 4-20 mA, sink or source, alarm and fault, while an optional HART 7 digital output supports easy configuration and diagnostic capability for preventive maintenance strategies. The new flame detector carries Safety Integrity Level (SIL 2), ATEX, IECEX and usFMc certifications.

Two versions are available: with or without on-board HD video output. The HD video option offers real-time monitoring of the area and automatic video recording during alarms for detailed post-event analysis.

“Users of our Spyglass Xtend can take advantage of a considerably longer detection range, while response times are much faster compared with existing UV/IR technology,” explained Régis Prévost, product line manager at Teledyne GFD. “The result? Earlier detection of hydrogen and/or hydrocarbon flames, protecting workers and minimising damage to your premises and assets. It’s also worth pointing out that the hydrogen flame detection performance of the Spyglass Xtend matches that of our existing Spyglass IR3-H2, which is dedicated solely to hydrogen.”

The oil and gas industry is

MSA Safety answers some common questions about hydrogen sulphide gas (H2S), and the differences between low and high concentrations

Hydrogen sulfide (H2S) gas can be fatal at high concentrations. But even low concentrations can cause health issues, particularly with prolonged exposure. So how can you best protect workers and minimise downtime?

What is H2S gas?

Hydrogen sulfide is a highly flammable, toxic and corrosive gas found in several industries including oil and gas, wastewater and chemical processing. It’s sometimes called ‘sour gas’, ‘sewer gas’ or ‘stink damp’ because of the way it smells like rotten eggs. However, H2S can’t reliably be detected by smell as it quickly deadens the sense of smell (a process known as ‘olfactory desensitisation or fatigue’).

How dangerous is H2S?

Exposure to high levels of H2S can be fatal, leading to loss of breathing, coma, seizures and death. It’s the second most common cause of fatal gas inhalation exposure in the workplace, second only to carbon monoxide.
H2S can also be harmful at low concentration levels, causing headaches, dizziness, nausea, breathing difficulties and a sore throat. These health impacts can become more serious with prolonged exposure.

Low concentration vs. high concentration H2S – exposure limits

The health impacts of H2S depend on how much is inhaled and for how long. The recommended exposure limit set by NIOSH (the US National Institute for Occupational Safety and Health) for ten minutes is 10 ppm. However, some U.S. states have developed ambient air standards for H2S well below OSHA and NIOSH standards due to concerns about health risks from chronic exposure.

For longer exposures to H2S, the recommended limits are much lower. For example, if you’re exposed for up to 24 hours, the World Health Organisation (WHO) recommends a maximum exposure of 0.1 ppm.
In response to concerns about the risks of H2S to human health even at low concentration levels, some countries have introduced equally stringent guidelines requiring businesses to monitor H2S at such concentrations. That’s why we’ve recently updated our ALTAIR io™ 4 Connected Gas Detector, offering the option of a low-concentration hydrogen sulfide sensor that can detect H2S at very low levels.

H2S in industry – the different sector impacts

H2S creates safety challenges for many industries. But some industries are more likely to be affected. These include:

Oil, Gas & Petrochemical

Oil, gas and petrochemical facilities handle raw ‘sour’ gas and oil which are naturally high in H2S. Extraction and refining processes release H2S, which may accumulate in confined, poorly ventilated spaces like processing units, pipelines and storage tanks. Closed systems with high-pressure conditions amplify the risks for workers.

Balancing safety and operational efficiency is an ongoing challenge in the oil, gas and petrochemical industry. Some are tackling this challenge by integrating new technological solutions into their safety management practices.

Waste water management

Wastewater facilities such as closed pipelines and sludge tanks have low oxygen levels and so provide the ideal conditions for H2S buildup. One of the key risks for wastewater workers is when they are entering confined spaces such as tanks and sewer lines. For many waste water management businesses, real-time monitoring of gas levels is considered a must-have.

Steel production

The steel industry’s use of high-temperature processes and sulfur-rich materials can lead to the release of H2S, creating hazards for workers. Confined, poorly ventilated spaces and desulfurisation units pose particular risks.

Preventative measures – safeguarding workers

Given the well-documented risks of H2S to workers, safety managers are seeking out effective preventative measures, including regular training and effective ventilation. The use of Personal Protective Equipment is also important.

A particularly helpful method for avoiding excessive H2S exposure is constant monitoring by advanced gas detection systems such as our ALTAIR io 4 Connected Gas Detector. Such systems can give you an early warning of even subtle increases in H2S concentration, helping you stay ahead of potential risks. Our updated ALTAIR io 4 device can detect subtle changes in H2S concentration levels at a resolution of 0.1 ppm, offering enhanced protection to workers. The default configuration for low-concentration H2S detection starts at 0.3 ppm, but customers may choose to configure the device to detect H2S starting at 0.0 ppm. This capability is particularly important in industries like oil and gas where companies wish to monitor low levels of H2S. Our low-concentration H2S sensor also offers processes designed to streamline regulatory compliance, minimising downtime and allowing readiness even for large-scale operations.

As with all toxic gases, early detection of H2S is an excellent way to alert safety managers to small increases in H2S emissions so they can help workers avoid harmful exposure, even at low concentrations.