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Summary
Summary
Whether occurring accidentally or through acts of terrorism, catastrophic chemical releases must be identified early in order to mitigate their consequences. Continuous sensor monitoring can detect catastrophic chemical releases early enough to curb extreme amounts of damage. In several notable instances, such monitors have not been used appropriately, or have fallen short of what they should have been capable of delivering. This book provides the technical background and guidance needed to get the most from this emerging technique and details the essentials of preparing any workplace from falling victim to a gas-leak catastrophe.
Author Notes
Since 1985, the Center For Chemical Process Safety (CCPS) has been the world leader in developing and disseminating information on process safety management and technology. CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over eighty books in its process safety guidelines and process safety concepts series.
Table of Contents
1 Introduction | p. 1 |
1.1 Purpose | p. 1 |
1.2 Scope | p. 1 |
1.3 Who Will Benefit from this Guideline? | p. 2 |
2 Management | p. 3 |
2.1 Management Overview | p. 3 |
2.2 Why Do We Use Gas Detectors? | p. 4 |
2.3 What Do We Want to Detect? | p. 5 |
2.4 What Actions Do We Expect to Undertake in the Event of a Release? | p. 6 |
2.5 How Much Should We Spend on Detection? | p. 7 |
3 Determining Where Gas Detection May or May Not be Beneficial | p. 9 |
3.1 Assessing Where Gas Detection may be Beneficial | p. 9 |
3.2 Situations Where Other Technologies May be More Beneficial | p. 11 |
3.3 Situations Where Gas Detection Is Recommended by Consensus or Mandated By Law | p. 13 |
3.4 Situations Where Toxic Gas Detection May be Beneficial | p. 17 |
3.5 Situations Where Combustible Detection May be Beneficial | p. 18 |
3.6 Example Applications of the Continuous Monitoring System | p. 20 |
3.6.1 Generalized Applications | p. 20 |
3.6.2 Personal Direct Reading Monitors in the Refining Environment | p. 22 |
3.6.3 Perimeter Monitoring at an LPG Storage Facility | p. 23 |
3.6.4 Exhausted Enclosures; Specific Example in the Semiconductor Industry, Specialty Gas Guideline | p. 24 |
3.6.5 Example: Hazardous Gas Monitoring: Alarm Set points and Response Protocols | p. 26 |
3.6.6 Hazardous Gas Monitoring: System Features | p. 27 |
3.6.7 Hazardous Gas Monitoring: Sample Points | p. 28 |
3.7 References | p. 29 |
3.8 Glossary | p. 29 |
4 Sensor Technology | p. 31 |
4.1 Introduction | p. 31 |
4.2 Description of Gases and Vapors | p. 31 |
4.2.1 Gas | p. 31 |
4.2.2 Vapor | p. 31 |
4.3 Available Sensors and How they Work | p. 32 |
4.3.1 Electrochemical Sensors | p. 32 |
4.3.2 Infrared (IR) Sensors | p. 32 |
4.3.3 Catalytic Bead Sensors | p. 33 |
4.3.4 Photoionization Detector (PID) | p. 33 |
4.3.5 Thermal Conductivity (TC) Gas Detectors | p. 34 |
4.3.6 Colorimetry (i.e., Honeywell Zellwegger Chemcassette®) | p. 34 |
4.3.7 Radon Gas | p. 34 |
4.3.8 Laser Gas Analyzer Open Path Detection | p. 34 |
4.4 Factors to Consider when Choosing a Sensor | p. 35 |
4.4.1 Target Gas/Vapor | p. 35 |
4.4.2 Interfering Gases/Vapors | p. 35 |
4.4.3 Expected Gas/Vapor Concentration Range | p. 35 |
4.4.4 Fixed vs. Portable Detectors | p. 36 |
4.4.5 Personal Detection Equipment | p. 37 |
4.4.6 Point or Open Path Detection | p. 37 |
4.5 Sensor Performance Variables | p. 38 |
4.5.1 Response Speed | p. 38 |
4.5.2 Measurement Range/Operating Range | p. 39 |
4.5.3 Sensitivity | p. 39 |
4.5.4 Oxygen Requirements | p. 39 |
4.5.5 Interference | p. 39 |
4.6 References | p. 43 |
4.7 Glossary | p. 44 |
5 Approaches to Detector Placement and Configuration | p. 45 |
5.1 General Guidance for Detector Placement and Configuration | p. 45 |
5.2 General Guidance for Toxic Gas Detection | p. 47 |
5.3 General Guidance for Flammable Detection | p. 50 |
5.4 Detector Placement for Source Monitoring | p. 51 |
5.5 Detector Placement for Volumetric Monitoring | p. 53 |
5.5.1 Applying the Volumetric Approach in Enclosed Buildings | p. 56 |
5.5.2 Applying the Volumetric Approach in Outdoor Locations and Semi-Enclosed Volumes | p. 58 |
5.5.2.1 Semi-Enclosed Volumes | p. 58 |
5.5.2.2 Open Volumes | p. 59 |
5.5.2.3 Applying the Volumetric Approach to Liquid Phase and Heavier-Than-Air Releases | p. 60 |
5.6 Detector Placement for Enclosure Monitoring | p. 60 |
5.6.1 Monitoring Enclosures for Toxics | p. 60 |
5.6.2 Monitoring Enclosures for Flammables | p. 63 |
5.6.2.1 Enclosures Containing Release Sources | p. 63 |
5.6.3 Enclosures Exposed to External Release Sources Only | p. 66 |
5.7 Detector Placement for Path of Travel and Target Receptor Monitoring | p. 68 |
5.8 Detector Placement for Perimeter Monitoring | p. 69 |
5.9 Detector Set Points and Monitoring | p. 71 |
6 Overall System Management - Commissioning, Testing, and Maintenance | p. 73 |
6.1 Summary | p. 73 |
6.2 Training | p. 73 |
6.3 Documentation | p. 74 |
6.4 Maintenance | p. 74 |
6.5 Establish a Good Relationship with the Local Authority-Having Jurisdiction (AHJ) | p. 75 |
6.6 Change Management | p. 75 |