Gas Production Industry Gas Detection Solutions: Nexisense Safeguards High-Risk Production Safety

Gases are indispensable raw materials in modern industry, widely used in refrigeration, fertilizer synthesis, metal protection, synthetic materials, medical, and food preservation. Common industrial gases include oxygen, nitrogen, argon, carbon dioxide, liquefied petroleum gas (LPG), hydrogen, methane, hydrogen sulfide, sulfur dioxide, isobutylene, etc. Most are flammable, explosive, toxic, or high-pressure. Leaks during production, filling, storage, or transport can cause fire, explosion, poisoning, or suffocation, leading to serious casualties, property loss, and environmental pollution.

With strict enforcement of the Regulations on the Safety Management of Hazardous Chemicals and the Industrial Gas Production Safety Code, gas production companies must establish comprehensive gas leak monitoring systems for real-time online monitoring, automatic alarms, and emergency linkage. Nexisense focuses on industrial gas sensing technology. Its SGA-500 online gas detectors, SGA-600 portable series, and supporting alarm controllers provide high-precision, corrosion-resistant, explosion-proof performance, enabling proactive safety management, ensuring production continuity and regulatory compliance.

Typical Risks and Monitoring Necessity in Gas Production

Gas production involves high-pressure filling, liquefaction and separation, pipeline transport, and bottling storage. Risks vary by stage:

• Filling stations and storage tanks: LPG, hydrogen, methane leaks can accumulate explosively; oxygen leaks may ignite in contact with grease.

• Pipelines and valve areas: hydrogen sulfide, sulfur dioxide leaks spread quickly, threatening nearby personnel.

• Bottling workshops and storage: nitrogen, argon leaks cause oxygen deficiency; isobutylene and other volatile gases can form explosive mixtures.

• Laboratories and quality control: standard gas cylinders (e.g., H2S) may leak; even low concentrations pose long-term risk.

These characteristics require monitoring systems with high sensitivity (ppm-level), fast response (<30s), interference resistance (temperature, humidity, dust), and explosion-proof, corrosion-resistant design. Traditional manual inspections are insufficient and delayed. Professional online monitoring provides 24/7 coverage, linking alarm controllers to ventilation, valve shutoff, and emergency stop, significantly reducing accident probability.

Core Advantages of Nexisense Gas Detection Products

Nexisense products use imported sensors with secondary calibration, temperature and humidity compensation, signal amplification, and circuit optimization, suitable for high-pressure, corrosive, and explosive gas production environments.

SGA-500 Online Gas Detector

Designed for fixed points such as storage tanks, filling lines, and pipeline valve groups:

• Gas coverage: LPG (0-100%LEL), oxygen (0-30%VOL), nitrogen (oxygen deficiency alarm), H2S (0-100ppm), SO2 (0-100ppm), methane (0-100%LEL), isobutylene (0-100ppm), supporting multi-channel.

• Output and protection: 4-20mA, RS485 Modbus-RTU, relay; Ex d IIC T6 Gb explosion-proof, IP65/66, stainless steel corrosion-resistant.

• Alarm and linkage: adjustable high/low thresholds (e.g., H2S 5/10ppm, LPG 20%LEL), response time<30s, linkage with ventilation, valve shutoff, or emergency stop.

• Environmental adaptability: -20℃ to +50℃, 0–95%RH, sensor lifespan 2–5 years. Factory calibrated, plug-and-play, long maintenance cycle.

  
  

SGA-600 Portable Gas Detector

Suitable for inspection, maintenance, and emergency response:

• Flexible sampling: diffusion, pump, or probe type; probe extends into valves or cylinders for safe sampling.

• Intelligent functions: data storage, average calculation, temperature/humidity display, unit switching, audible/visual/vibration alarms.

• Portable design: weight

  <500g, battery="" life="">8 hours, explosion-proof certified.

SGA-800 Alarm Controller

Installed in control rooms or security offices:

• Multiple input channels (branch/loop), unified power, display, and recording.

• Linkage extension: triggers fans, valve shutoff, audible/visual alarms, SMS notifications.

• Data recording: export historical curves, supports compliance audits.

The system forms a complete "monitoring-alarm-response" loop.

Typical Application Scenarios and Market Validation

• Liquefied gas filling stations: SGA-500 monitors LPG leaks, automatically shuts off flow if exceeded.

• Hydrogen/oxygen pipeline areas: monitors combustible gas and oxygen concentration, preventing explosions.

• H2S standard gas laboratories: dual online + portable monitoring ensures safety.

• Bottled gas storage: SGA-600 inspects oxygen deficiency and volatile gases.

Feedback from multiple gas companies: integrating SGA-500 + SGA-800 reduced leakage incidents by 60%, emergency response time shortened to minutes, successfully passing safety assessments.

Practical Advice for Implementing Gas Detection Systems

Evaluate gas type, concentration range, and installation points. Position detectors upstream in areas prone to gas accumulation. Calibrate periodically (every 6–12 months) using standard gas cylinders. Integrate with IoT to upload data to cloud platforms for predictive maintenance and compliance reporting.

Frequently Asked Questions (FAQ)

Q1: Which common gases are supported by Nexisense SGA-500? Can measurement range, sensor type, or alarm threshold be customized by gas type or production stage?
A1: Standard coverage: LPG (0–100%LEL or 0–50%VOL high concentration), H2 (0–100%LEL), O2 (0–30%VOL oxygen deficiency alarm), N2 (oxygen deficiency monitoring), H2S (0–100ppm), SO2 (0–100ppm), CH4 (0–100%LEL), isobutylene (0–100ppm), supporting multi-channel combinations. Customization available for filling stations, pipelines, H2S labs, and storage areas. Prototype delivery usually 4–8 weeks, ensuring seamless integration with PLC/SCADA and emergency shutoff systems.

Q2: How is the long-term stability and interference resistance of SGA-500 in high-pressure, corrosive, explosive environments? Any protective recommendations?
A2: 316L stainless steel housing + acid/alkali and grease resistant coating, IP65/IP66, Ex d IIC T6 Gb certified, operating -20–+50℃, 0–95%RH. Built-in advanced temperature/humidity compensation, multi-level digital filtering, EMI shielding. Recommended: avoid direct spray or high-pressure valves, add explosion-proof shield, clean monthly, quarterly zero calibration, install pre-filters in corrosive zones, use shielded cables in EMI areas. Sensor lifespan 3–5 years.

Q3: How is safety and usability ensured for SGA-600 during cylinder inspection, pipeline maintenance, or emergency response?
A3: Ex ib intrinsic safety, suitable for Zone 0/1. Probe 1–2m, allowing sampling at safe distance. Audible/visual/vibration alarms, customizable thresholds. Ergonomic:<500g, one-hand="" 12h="" usb-c="" fast="" data="" storage="">100,000 points, export to Excel/CSV.

Q4: How does the system integrate with PLC, security, or SCADA systems?
A4: SGA-500 supports 4–20mA, RS485 Modbus-RTU, relay dry contacts, compatible with Siemens S7, Honeywell Experion, ABB 800xA. Free protocol manuals, ladder diagrams, function blocks, real-time monitoring software. Integration 1–3 weeks. SGA-800 expandable to 32 channels, MQTT cloud upload, remote monitoring.

Q5: What factors affect sensor life and maintenance costs?
A5: Electrochemical sensors (H2S, SO2, isobutylene) 2–4 years; IR/catalytic (LPG, H2, CH4) 4–6 years. Affected by high concentration exposure, dust/grease, extreme temperature/humidity, frequent pressure surges. Recommended: monthly visual inspection, quarterly zero calibration, annual full calibration, multi-stage filtering in corrosive zones. Annual maintenance ~12–18% of equipment cost. Modular sensor replacement 10–15 min onsite.

Q6: Are products certified and compliant with national and international standards?
A6: Certified: CMC type approval, Ex d IIC T6 Gb / Ex ib IIC T4 Gb, EMC tested. Complies with hazardous chemicals regulations, industrial gas production safety codes, GB standards. Data usable for safety audits, occupational health, and environmental compliance. Export products also IECEx/ATEX, CE, RoHS certified with bilingual certificates.

Q7: How does the system respond to over-limit gas concentrations and avoid false alarms?
A7: Three-level alarm (pre-alarm/alarm/high), configurable thresholds, delay, and linkage. Responses: audible/visual ≥90dB, relay control fans/valves/lights, RS485 alarm to control room, optional SMS/APP notifications. False alarm control: trend analysis, averaging, compensation, manual reset. Typical setup: pre-alarm ventilation only, high-limit valve shutoff, false alarm rate<1%.

Q8: How to quickly get customized solutions, prototype trials, or on-site support?
A8: Contact Nexisense via website or sales/tech support with gas type, pressure/flow, layout, target concentration, installation points, PLC type, budget. Usually 24–48h response with detailed selection, weight/power, integration, quote, and case examples. Optional free trial 1–2 months with installation guidance, simulated gas test, linkage validation, data analysis, or on-site engineer service.

Conclusion

Gas production safety is a lifeline for the industry. Nexisense series delivers precision and durability, helping prevent leaks and ensuring continuous production. Deployment of professional monitoring systems in high-pressure, high-risk environments supports sustainable and safe operations. Nexisense continues innovating to safeguard gas industry safety.