Fire Safety Industrial Gas Detection Solutions: How Nexisense Supports Safe Production in Factory Workshops

In numerous industrial scenarios such as chemical, steel, coal, petrochemical, semiconductor, synthetic materials, biopharmaceutical, pharmaceutical, laboratories, coking, tobacco, boilers, and metallurgy, gases are almost everywhere. From raw material handling and production processes to finished product storage, each step may involve multiple gases. Flammable and explosive gases (such as methane, hydrogen, propane) and toxic or hazardous gases (such as carbon monoxide, hydrogen sulfide, ammonia, chlorine) can, once leaked, cause anything from equipment disruption to fires, explosions, poisoning incidents, and even personnel casualties and major property losses.

Therefore, modern factory workshops commonly deploy multi-level fire safety systems, including ventilation, automatic fire suppression, audible and visual alarms, and emergency broadcasting. Among these, gas monitoring and alarm systems are undoubtedly the most fundamental and direct line of defense. They can detect gas concentration changes in real time, provide warnings before danger thresholds are reached, and trigger linkage measures to control risks at the earliest stage.

Faced with complex and variable industrial gas environments, how can enterprises choose a reliable gas detection solution? Nexisense provides one-stop support from sensors to complete systems, helping companies build an efficient and stable gas safety network.

Why Factories Must Prioritize Gas Detection

Industrial gas risks have two main characteristics: concealment and suddenness:

• Concealment: Many toxic gases (e.g., CO) are colorless and odorless, making them difficult to detect by human senses; some combustible gases show no obvious characteristics at low concentrations.

• Suddenness: Aging pipelines, valve leaks, operational errors, and equipment failures can release large amounts of gas instantly, leaving only seconds to react.

Statistics show that over 60% of industrial accidents caused by gas leaks worldwide lacked effective monitoring and early warning in the initial stage. Early alarms and linkage to ventilation, gas cutoff, or sprinkler systems could prevent or greatly reduce many accidents.

As a result, national and industry standards (such as GBZ 2.1 “Occupational Exposure Limits for Harmful Factors in the Workplace” and AQ/T 3048 “Technical Specifications for Gas Detection and Alarm Systems in Chemical Enterprises”) clearly require high-risk areas to install fixed gas detectors integrated with alarm and linkage systems.

How to Choose Suitable Gas Detectors for Industrial Scenarios

Selection may seem simple but requires comprehensive consideration of the following key factors:

1. Target gas: Single gas or multi-gas combination? Common combinations include combustible gas + CO + H₂S + O₂ (4-in-1), or process-specific gases like VOC, SiH₄, NH₃, Cl₂.

2. Concentration range and accuracy: LEL monitoring should cover 0–100% LEL; toxic gases must meet occupational exposure limits (PC-STEL/PC-TWA).

3. Installation environment: Explosive areas require Ex d IIC T6 Gb or above; humid, dusty, or high-temperature environments require IP65+ and durable sensors.

4. Signal output and compatibility: 4-20mA, RS485 Modbus RTU, switch output, wireless, etc., must match existing PLC, DCS, or SCADA systems.

5. Reliability and certification: Check for CE, RoHS, ISO9001, ISO14001, CPA type evaluation, third-party metrology certification, explosion-proof certification.

6. After-sales and brand strength: Response speed, spare parts supply, and technical support directly affect long-term stability.

Nexisense Core Products

Online Fixed Gas Detector – SGA-500 Series

This highly integrated explosion-proof online detection and alarm device combines gas detection, concentration display, alarm settings, switch output, 4-20mA/RS485 signal output, LCD display, intelligent zero/span calibration, and sensor life reminder.

• 24V DC power, plug-and-play

• Supports multiple sensor types (catalytic combustion, electrochemical, infrared, PID, photoionization)

• Robust explosion-proof housing, suitable for Zone 1/Zone 2

• Built-in high-brightness LCD for on-site concentration and status

• Multiple alarms (audible, visual, relay, signal output)

Widely used in chemical parks, petrochemical plants, pharmaceutical workshops, and semiconductor factories, with easy installation, minimal drift, and low maintenance.

Alarm Controller – SGA-800 Series

Centralized alarm controllers improve efficiency in multi-point monitoring. SGA-800 supports 4, 8, 16+ channels, powers connected detectors, collects and displays concentrations, and provides large-screen display, audible/visual alarms, historical data storage, RS485/Ethernet for integration.

Linkage capabilities:

• Multiple 220V/5A relays to control fans, solenoid valves, pumps

• Supports area-based, time-based, multi-level linkage

• Expandable for complex control strategies

System Integration and Linkage

SGA-500 detectors provide 24V/1A passive NO/NC outputs for small devices. For larger needs, controllers enable:

• Gas concentration exceeds threshold → automatic fans

• High-high alarm → cut gas valves + start sprinklers

• Data upload to PLC/DCS → centralized monitoring, trend analysis, reporting, remote viewing

Typical Applications

• Semiconductor & electronics: monitoring SiH₄, PH₃, AsH₃, B₂H₆ using PID or IR detectors.

• Pharmaceutical & bio labs: VOC, formaldehyde, H₂O₂, ozone monitoring with portable and fixed devices.

• Petrochemical storage: large-scale combustible + toxic gas detection linked to sprinklers and water curtains.

• Metallurgy coking: high temperature, humidity, dust environments, anti-clog sensors for CO, H₂S, SO₂.

  
  

FAQ

1. Which gases does SGA-500 support? Can it monitor multiple gases simultaneously? Modular sensor design supports catalytic, electrochemical, IR, PID, semiconductor. Covers combustible gases (methane, propane, H₂, acetylene), toxic gases (CO, H₂S, NH₃, Cl₂, SO₂, NOx, HCN), O₂, VOC, CO₂, and semiconductor gases (SiH₄, PH₃, AsH₃). Single-unit high-precision monitoring; 2–4 gases require 4-in-1 or multi-sensor customization.

2. Explosion-proof rating and applicable zones? Ex d IIC T6 Gb / Ex tb IIIC T80℃ Db, suitable for Zone 1/2 and dust zones 21/22; meets GB3836, GB12476, and related standards.

3. SGA-800 max channels and communication distance? Standard 4, 8, 16 channels; RS485 up to ~1200m. Recommend ≤16 detectors per segment for stability.

4. Integration with PLC/DCS/SCADA? Supports 4-20mA, RS485 Modbus RTU, optional Modbus TCP/Ethernet IP; compatible with Siemens, Schneider, Rockwell, Omron, Mitsubishi, Honeywell, Emerson DeltaV, Yokogawa Centum VP.

5. Sensor lifespan and calibration cycle? Electrochemical 2–3 years, catalytic 3–5 years, IR >5 years, PID 1–3 years. Life prediction alerts<30%, calibration every 6–12 months.

6. Wireless deployment possible? LoRa 433/868/915MHz, 4G/5G gateway; AES-128 encryption, 2–5 km range, supports relay and signal monitoring.

7. Multi-level alarm and regional control? Supports 3-level thresholds with independent outputs; expandable for complex logic.

8. How to get full manuals, 3D models, or project references? Contact via website or hotline; manuals, 3D STEP/IGES, project cases provided; quote 1–3 days standard, 5–10 days custom/bulk.

Conclusion: Choose Nexisense to Safeguard Every Inch of Production Safety

Gas safety affects production continuity and personnel safety. Nexisense provides reliable, flexible, cost-effective solutions from sensors to full monitoring systems. Contact Nexisense professional team for tailored advice and on-site inspection. Safety starts with each detector.