Code Compliant Gas Detection / Leak Detection Emergency Alarm Systems

There are existing codes that do require gas and leak detection emergency alarm systems!

In working with several ethanol plants recently, I’ve heard comments from several people that they were waiting for guidance from code issuing organizations before implementing gas detection / leak detection emergency alarm systems in their facilities. Given the hazards present in an ethanol production facility, and the number of incidents reported, I think it’s clear that we can’t sit back and wait for specific codes to be published for the ethanol industry; and with the tools we have today, there really isn’t any need to wait. There are plenty of existing code requirements requiring gas detection / leak detection emergency alarm systems that are already published that have been overlooked in the construction of ethanol facilities. In order to apply these codes correctly a Process Hazard Analysis (PHA) / Code Compliance Audit (CCA) must be performed with gas and leak detection in mind. Once the PHA-CCA is completed the requirements for a gas detection / leak detection emergency alarm system can be defined. Following is a brief outline of the steps involved in conducting a PHA-CCA:

1) Performing the PHA-CCA is the first step in determining where a facility stands relating to gas detection / leak detection and emergency alarm system requirements. Not only will this step define what is already in place, but will also define what is required to come into design compliance. The PHA-CCA will take into account and address the following:

a) Identify the type and quantities of hazardous materials in use, the applicable code hazard classifications, the quantities and methods of use of all applicable hazardous material used in the facility.

b) Identify the location of potential sources of leaks of each hazardous material.

c) Identify type and function of applicable leak monitoring and detection device technology, alarm annunciation, interlock, and control logic required for each hazardous area zone to meet the requirements of the defining codes. This will include: control of automatic shutoff valves, manual emergency alarm initiation devices, emergency alarm notification devices, signage, Fire Alarm supervision and response, etc.

d) Identify and note all applicable code references for each required device in the system and the function of each device. This is critical and becomes a major part of the Fire Marshal Design Submittal Package used for approval and to meet the code requirements regarding proper content of your Permanent Site Records information.

e) The PHA-CCA will be performed for each hazardous material in use in the facility.

f) An airflow movement analysis will be performed and documented as part of the PHA-CCA. See item #2 below.

2) Airflow Movement Analysis.

a) An airflow movement analysis is provided in order to identify the proper location and quantity of gas detection sensors required for each area. This is accomplished by a ventilation air movement analysis of each zone under normal operational ventilation conditions and under alarm ventilation conditions (i.e. purge fan on, etc.). This is included in the PHA-CCA package. One method of accomplishing this task is by smoke testing. The information obtained in this portion of the report is reviewed by the Fire Marshal during the design approval process.

b) Additionally, the Fire Marshal may want smoke released during his acceptance testing procedures after the system is installed, to mimic the target hazard characteristics, and ensure that a gas leak will actually come in contact with the sensor. Airflow testing and movement analysis is documented on AutoCAD drawings provided with the report. Additionally, a DVD will be provided to the owner for his record purposes, showing the actual airflow tests being performed and the test results. We video all of our airflow testing for verification and liability purposes.

Finally, Ino-Tek will be exhibiting at the upcoming Fuel Ethanol Workshop (FEW) show in Nashville in booth #2616. We will also be hosting a Gas Detection Technology Forum at the Radisson Hotel at Opryland. Please feel free to come and visit us to discuss the process we use to correctly implement a properly designed, code compliant, gas detection / emergency alarm system. Following are the details for our Gas Detection Technology Forum:

Date: June 17, 2008

Time: 5:00 pm to 9:00 pm

Where: Radisson Hotel at Opryland, McGavock Ballroom A

RSVP: By calling Marianne @ 586-212-0561 or email to: marianne.taylor@ino-tek.com

Special

Guests: Ted Strojny, Draeger Systems

Dennis Blue, MSA

Bruce Royer, Honeywell