When facilities invest in emissions monitoring, combustion analysis, process control, or continuous emissions monitoring systems (CEMS), a great deal of attention is typically focused on the analyzer itself. However, one of the most common causes of inaccurate readings, excessive maintenance, and poor analyzer performance is not the analyzer—it is the gas sampling system.
A gas analyzer can only measure the sample it receives. If that sample is altered, contaminated, cooled, condensed, delayed, or otherwise unrepresentative of the process, the analyzer’s results become questionable regardless of how advanced the instrument may be.
The Purpose of a Gas Sampling System
A gas sampling system serves a critical role: delivering a representative sample from the process to the analyzer while preserving the sample’s composition and condition.
This often requires:
Temperature control to prevent condensation
Pressure regulation to protect instruments
Filtration to remove particulates
Moisture management
Flow control for consistent sample delivery
Fast-loop designs to reduce response time
Without these elements, measurement accuracy can quickly deteriorate.
Common Sampling System Challenges
Industrial processes often involve harsh conditions including high temperatures, moisture, corrosive gases, particulates, and fluctuating pressures. Poorly designed sample systems can create issues such as:
Long analyzer response times
Condensation within sample lines
Sample contamination
Component fouling
Increased maintenance requirements
Inaccurate process data
These challenges are especially common in combustion applications, emissions monitoring systems, power generation, manufacturing processes, and environmental compliance programs.
Key Design Considerations
1. Representative Sampling
The sample extraction point should accurately reflect the process stream. Poor probe placement or improper extraction methods can create biased results that do not represent actual operating conditions.
2. Temperature Management
Many gas streams contain moisture or compounds that can condense if temperatures fall below critical thresholds. Heated probes, heated lines, and proper insulation often play a vital role in preserving sample integrity.
3. Pressure Control
Analyzers typically require sample pressures that differ significantly from process pressures. Proper pressure regulation protects sensitive instrumentation while maintaining stable measurements.
4. Response Time
Slow response times can delay process decisions and obscure changing operating conditions. Minimizing dead volume and optimizing flow paths help ensure analyzers receive fresh, current samples.
5. Maintainability
A well-designed sampling system should simplify calibration, maintenance, troubleshooting, and component replacement. Easy access and modular designs can significantly reduce downtime and operating costs.
The Cost of Poor Sampling
Many facilities spend thousands of dollars troubleshooting analyzers when the root cause lies within the sampling system. Inaccurate measurements can lead to compliance risks, process inefficiencies, excessive fuel consumption, and unnecessary maintenance expenses.
Investing in proper sampling system design often provides a faster return on investment than upgrading analyzers alone.
Final Thoughts
Successful gas analysis starts long before the sample reaches the analyzer. A properly engineered sampling system protects sample integrity, improves reliability, reduces maintenance, and delivers the accurate data operators depend upon for critical decisions.
Whether you’re designing a new analyzer installation or troubleshooting an existing system, evaluating the sampling system should always be one of the first steps toward achieving dependable results.
The manufacture of lithium-ion (Li-ion) batteries is far more complex than simply assembling cells and packaging them up. It’s a rigorous chain of steps — from electrode preparation and cell assembly, to formation, aging, module and pack assembly, then testing and quality assurance. Each stage contributes to the battery’s performance and safety.
The Invisible Risks: Gases & Exposures
One of the less obvious but critically important aspects of battery manufacturing is gas monitoring. In Li-ion production, manufacturers may encounter gases that pose serious hazards — both for workers and for the facility.
For example:
Hydrogen can be generated during charging/discharging of batteries, and it introduces both fire and explosion risks.
Phosphine gas is used in some battery-component manufacturing processes. It’s highly toxic even at low levels.
Additional gases and vapours may include hydrogen chloride (HCl), ammonia (NH₃), hydrogen fluoride (HF), fluorine (F₂), chlorine (Cl₂) — all of which require vigilance.
This is where LEL (Lower Explosive Limit) gas detection comes into play. Monitoring for flammable or combustible gases helps ensure that any build-up of such gases is caught early, before a dangerous concentration is reached.
Why Uncontrolled Gas Emissions Are a Major Concern
When flammable or toxic gases accumulate in a manufacturing environment, the risks are two-fold:
Explosion and fire hazard: Imagine a closed room where hydrogen or another flammable gas builds up — without proper detection and ventilation, an ignition source could trigger a serious event.
Health hazard: Prolonged exposure to toxic gases can cause respiratory illness, neurological damage, or worse.
Effective gas-monitoring systems, paired with proper ventilation, protective gear, training, and emergency response plans, form the backbone of a safe Li-ion manufacturing facility.
The Role of Continuous Gas Monitoring
Continuous monitoring is not a nice-to-have — it’s essential. With reliable gas detection in place, manufacturers can:
Detect abnormal concentrations of flammable or toxic gases in real time.
Trigger alarms (visual and/or audible) so personnel can evacuate or take corrective action.
Integrate with ventilation systems to automatically flush hazardous gas out of the environment.
Maintain regulatory compliance and ensure the facility remains safe, productive, and efficient.
As demand for Li-ion batteries skyrockets (for EVs, grid storage, portable electronics and more), the need to protect manufacturing environments grows in parallel.
Regulatory Framework & Standards
Safety doesn’t stop at equipment and procedure — it extends into regulation. Manufacturers must stay aligned with industry standards like:
National Fire Protection Association (NFPA) codes — for instance, NFPA 70 (National Electrical Code) and NFPA 855 (Installation of Stationary Energy Storage Systems).
Standards from Underwriters Laboratories (UL) and International Electrotechnical Commission (IEC) — which cover battery design, testing, short-circuit protection, and fire hazards.
Local/regional regulations depending on the manufacturing site.
That means gas detection systems not only protect people and property — they’re also part of a framework that supports product quality, operational efficiency, and regulatory compliance. For example, early detection of leaks or irregularities can reduce waste and prevent costly downtime or product failures.
A Practical Toolset for Manufacturers
For Li-ion battery manufacturers, the right monitoring hardware matters. The original article highlights gas-monitoring solutions such as:
Fixed flammable gas monitors designed to detect hydrogen, methane, propane, butane and other combustible gases, housed in explosion-proof enclosures suitable for hazardous locations.
Universal gas monitors for toxic gases (e.g., ammonia, hydrogen fluoride, hydrogen chloride, hydrogen sulfide) with on-screen readouts and alarm indicators.
When chosen and calibrated correctly, these systems become an integral part of the manufacturing safety setup.
Final Takeaways
The manufacturing of lithium-ion batteries involves hidden risk factors like flammable and toxic gases; these must be managed proactively.
Continuous gas monitoring (especially LEL detection) is a key line of defense against fires, explosions and health hazards.
Compliance with NFPA, UL, IEC and local standards is crucial — not just for safety, but for product reliability and operational success.
Investing in the right monitoring equipment and safety protocols is not an expense — it’s foundational to a resilient, efficient Li-ion manufacturing operation.
By : PureAire Monitoring Systems Posted on : September 17, 2024 Combustible Gas Monitors, News Room
Thanks to their outstanding performance in the peak load range, gas turbines have proven themselves as crucial and reliable components in numerous industrial applications. Gas turbines are used especially frequently in the electrical and heat generation sector, as well as in the oil and gas industry. In industrial energy production, gas turbines ensure that consumption peaks are covered and produce heat for buildings. Frequent areas of use are gas turbine works, combined heat and power (CHP) plants and cogeneration plants. A particularly high level of energy efficiency can be achieved using a combination of gas and steam turbines. In the oil and gas industry, gas turbines are in use as mechanical drives for pumps, compressors and generators in the transportation and processing of raw materials. Gas turbines are operated with liquid and gaseous fuels such as natural gas, gasoline, diesel, heating oil or petroleum. Optimizing the fuel- and exhaust gas-intensive process to the highest level of efficiency involves a complex interaction between the exhaust gas parameters and the combustion process settings of the gas turbine – the basis for an optimum performance. For a service technician, it is important to understand the function of the combustion process and the influence of the individual measurement parameters on the performance and pollutant emission of gas turbines.
Functional principle of gas turbines
Turbine
Gas turbines are combustion engines which consist of three components: a preliminary compressor the central combustion chamber and the actual turbine. The design, performance and size of gas turbines differ depending on the application and area of use. However, their working principle is always the same, and is based on the thermodynamic cycle process according to James Prescott Joule (“Joule process”). Air is compressed via the blading of one or more compressor steps, and then mixes with a gaseous or liquid fuel in the combustion chamber, ignites and combusts.
A hot gas is produced from this mixture of compressed air and combustion gas, which can reach temperatures of +1,000°C, and which escapes to the downstream turbine component, and expands. Thermal energy is converted into mechanical energy. Subsequently, in the expansion turbine, the energy-rich, hot exhaust gas expands almost to ambient pressure, losing its velocity. During the expansion process, the exhaust gas transfers power to the turbine. Approximately 2/3 of this power is needed to drive the compressor (air intake). A directly coupled generator converts the mechanical energy into electrical energy. Roughly ¹/₃ of the power output remains available on the low pressure side for a second drive, for example for driving a generator, rotor, compressor or pump, before the hot gas is diverted to a downstream heat recovery boiler for the purpose of heating buildings.
Analyzing exhaust gas concentrations correctly
The concentration of the released exhaust gases provides important information on the efficiency of the combustion and how it can be increased. CO and NOX values provide information on the current status of the system and the adherence to the emission limit values. The air input between rich and lean and the correlating combustion chamber temperature influence the emission behavior of the gas turbine.
Challenges in commissioning, operation and servicing
In emission measurements in gas turbines, the challenge is measuring not only at very high, but also at very low gas concentrations. At the right operating point, optimally adjusted gas turbines emit only low levels of CO and NOX. However, high gas concentrations can occur, for example when the plant is started up for testing purposes. The reduction of NO2 emissions as well as the avoidance of pressure loss in the combustion chamber are also important factors for the efficient operation of the gas turbine.
For facilities across the manufacturing, energy, and transportation sectors, monitoring gaseous byproducts is essential to efficient and responsible operations. Advanced analytical instruments known as combustion analyzers and emissions analyzers provide valuable insights into different aspects of a company’s processes. However, these two technologies’ specific purposes and applications are often misunderstood.
In this in-depth guide, we will unravel the intricacies between combustion analyzers and emissions analyzers. You’ll learn how their capabilities complement each other to drive smarter business decisions, optimize efficiency, reduce environmental impact, and maintain regulatory compliance. Let’s dive in and shed light on selecting the ideal analyzer for your needs.
Combustion Analyzers: Optimizing Efficiency and Performance
Combustion analyzers measure the chemical components present in the byproducts of the combustion process itself. They are used to monitor and control combustion systems for maximum efficiency, safety, and performance.
These analyzers sample flue gases to quantify oxygen levels, carbon monoxide, nitrogen oxides, sulfur dioxide, and other substances. To optimize the system, the resulting data is used to adjust air-fuel ratios, equipment configurations, and combustion parameters.
Key applications of combustion analyzers include:
Optimizing the combustion efficiency of boilers and turbines at power plants, resulting in lower fuel usage and costs. Even small efficiency improvements translate into major savings and a reduced carbon footprint.
Helping manufacturers continually tune their furnaces and ovens to maximize product throughput while minimizing fuel consumption. This boosts profitability through energy savings.
Enabling engineers to develop cleaner combustion processes that curb emissions during research and development. Combustion analyzers provide critical data as next-generation systems are designed and tested.
Allowing technicians to properly configure and maintain combustion equipment by monitoring key equipment health and performance indicators. Analyzer data guides preventative maintenance to avoid costly unplanned downtime.
Providing facility managers and safety teams with early warning of hazardous conditions like carbon monoxide buildup or gas leaks. Prompt response avoids threats to worker health.
In summary, combustion analyzers are invaluable tools for optimizing the combustion process across various applications, from small commercial heaters to massive utility power plants.
Whereas combustion analyzers focus on the combustion byproducts within a system, emissions analyzers sample and analyze pollutants that have been emitted into the outdoor environment through exhaust stacks or industrial vents.
Emissions analyzersprecisely measure regulated air pollutants such as nitrogen oxides, sulfur dioxide, carbon monoxide, volatile organic compounds, and particulate matter. This data documents a facility’s compliance with air quality standards and emissions limits set by environmental regulatory agencies.
These continuous emissions monitoring systems are commonly deployed in industries such as:
Oil and gas, where refineries must demonstrate they meet emissions thresholds for pollutants released through cracking towers, catalyst regeneration, and other processes. Strict monitoring maintains compliance.
Power generation, where coal, natural gas, and even renewable energy plants must quantify stack emissions from generating units, boilers, turbines, and other equipment to adhere to permits.
Wastewater treatment, where plants incinerate sludge and gas byproducts from microbial digestion processes. Emissions analyzers ensure these incinerators destroy pollutants effectively and safely.
Transportation, where vehicle manufacturers rely on emissions analyzers to certify new models, meets emissions regulations as engine designs evolve.
In these and other industries, emissions analyzers are indispensable tools for environmental accountability and regulatory compliance. The analyzers provide definitive data that pollution control systems adequately protect our shared air.
Key Differences Between These Important Technologies
While combustion analyzers and emissions analyzers both measure gases, a few key differences determine which technology suits different applications:
Purpose: Combustion analyzers focus on optimizing the efficiency and performance of combustion systems. Emissions analyzers verify regulatory compliance through environmental monitoring.
Installation: Combustion analyzers can be deployed as portable systems or fixed installations. Emissions analyzers typically involve fixed, continuous monitoring systems.
Measured Gases: Combustion analyzers measure oxygen, carbon monoxide, and other gases within the combustion process flow itself. Emissions analyzers sample regulated pollutants emitted into the atmosphere.
Monitoring Location: Combustion analyzers sample gases within equipment like boilers and engines to analyze the combustion process. Emissions analyzers sample stack gases after pollution control systems to verify emissions leaving the site.
Data Application: Combustion analyzer data helps adjust combustion parameters for efficiency and performance. Emissions data proves regulatory compliance through rigorous documentation.
Recognizing these key differences helps clarify when each technology is most appropriate. Often, both analyzers play important complementary roles in comprehensive monitoring.
Additional Differences to Consider
Beyond the core differences in purpose, installation, gases measured, monitoring location, and data application, some additional nuances distinguish these technologies:
Combustion analyzers used for optimizing efficiency often employ sensors that provide rapid response times, allowing operators to see the impact adjustments make in real-time. Emissions monitors emphasize meticulous accuracy over speed.
While combustion analyzers read internal gases in situ, emissions analyzers may use a sample extraction and conditioning system to handle hot, dirty stack gases before analysis.
The wide range of regulated pollutants requires emissions analyzers to employ various sensor technologies. Combustion analyzers focus on key gases like O2, CO, and NOx.
Due to control system fluctuations, the composition of stack gas emissions is more variable than the byproducts within combustion chambers. Emissions analyzers must adapt to these variations.
Since combustion analyzers improve profitability, their ROI is readily apparent. The value of emissions monitoring for compliance is less tangible but equally important.
These less obvious factors also inform the selection process. The experts at Highmark Analytics can elucidate these technical nuances and match solutions to your specific requirements.
Expert Guidance for Developing Your Gas Analysis Strategy
The versatility of advanced gas analyzers like combustion analyzers and emissions analyzers offers flexibility but can also present challenges when developing a monitoring strategy tailored to your organization’s specific needs.
The engineers at Highmark Analytics have over 20 years of experience helping customers select and implement gas analysis solutions across a vast range of industries and applications. Our technical team comprises experts in combustion analysis and environmental compliance monitoring.
Whether you require portable combustion analyzers for maintenance, continuous emissions monitoring for regulatory mandates, or a comprehensive solution combining technologies, Highmark Analytics has the products and expertise to help you achieve your efficiency, emissions, and compliance goals.
Contact Highmark Analytics today to evaluate your needs. Our gas analysis specialists can help you navigate specifications, standards, integrations, data management, and the complex regulatory landscape to develop a successful plan for effectively applying these monitoring tools.
Investing in the right technology and expert guidance paves the way to more profitable and sustainable operations. Highmark Analytics is there every step of the way, from initial consultation to ongoing training and support.
Dealing with hazardous gas leaks in an industrial facility can have severe consequences if not handled quickly and correctly. Gas leaks pose very serious risks to human health and safety, result in production downtime, and can cause catastrophic explosions and environmental damage if ignited. That’s why implementing comprehensive gas leak prevention and detection strategies is essential and should be a top priority for any business utilizing gases in their operations.
Industrial gases like methane, propane, and hydrogen are highly flammable. Toxic gases used in operations, such as ammonia and chlorine, can cause immediate and long-term health effects if leaked. Even inert gases like helium and argon can create hazardous conditions by displacing breathable oxygen if they accumulate. Plus, any leaks of greenhouse gases contribute to air pollution and environmental concerns. Implementing comprehensive prevention and detection strategies is key to creating a safe working environment. Here are some critical tips to help your business proactively address the serious risk of gas leaks:
Conduct Regular Thorough Equipment Inspections
One of the very best ways to get ahead of potential gas leaks is through detailed inspections on a routine basis. Develop a schedule for frequently thoroughly checking all gas machinery, piping, tubing, valves, fittings, and connections. Train maintenance staff extensively on what to look for during inspections, such as corrosion, loose fittings, cracks, dents, defective seals, and any other damage. Document any issues discovered, no matter how minor, and implement repairs immediately. Staying on top of equipment conditions diligently reduces leak risks.
Install Advanced Gas Detection Systems
Proper gas detection systems alert you quickly to any leaks so immediate action can be taken. Consider both continuously running fixed detectors located in critical areas and portable detectors that can be used to spot-check for leaks periodically. Systems are available to detect a wide range of industrial gases based on your specific needs, including combustible gases, VOCs, greenhouse gases, and toxins. Look for self-calibrating “smart sensor” systems that ensure accuracy. Partner with an experienced and trusted provider to select and install the optimal gas detection equipment for your facility.
Implement a Detailed Leak Response Plan
Ensure all employees understand how to respond if a gas leak is detected. Your response plan should cover step-by-step evacuation procedures, who to contact for repair, how to safely shut off gas valves, where to access safety gear, and how to properly operate gas detection equipment. Post emergency response information visibly throughout the facility. Also, regular in-depth training should be provided to keep the plan at the forefront of the mind. Advanced preparation ensures leaks are handled appropriately and promptly.
Perform Regular Pressure Decay Testing
Pressure decay testing, also called leak decay testing, is a common and effective preventative technique. It involves pressurizing equipment like pipes, valves, pumps, or tanks above normal levels and monitoring pressure over time. Any significant unexplained pressure drop indicates a likely leak. Schedule this testing routinely during planned maintenance outages. Frequent testing identifies developing issues early before leaks worsen.
Address All Safety Risks
Look critically at all potential ignition sources and activities that could possibly spark a gas explosion if a leak occurred. Completely prohibit smoking near gas equipment and storage areas. Install proper ventilation systems to dissipate leaks quickly. Ensure all electrical wiring and connections are perfectly up to code and rated for hazardous areas. Reduce clutter that could hinder leak detection. A tidy, safety-focused workspace is essential for minimizing risks.
Partner with a Gas Leak Detection Expert
While maintenance staff can handle basic inspecting and testing for leaks, specialized skills and equipment are absolutely needed for in-depth leak detection and precise pinpointing of leak locations when issues arise. Partnering with an experienced and certified firm like Highmark Analytics provides that critical expertise. Our technicians use advanced methods and high-tech tools to detect even small leaks and recommend repairs. Rely on knowledgeable specialists for safety.
Conduct Continuous Ambient Air Monitoring
Installing fixed ambient air monitoring systems is another way to catch leaks proactively 24/7. These systems continually sample surrounding air to measure gas levels and immediately detect any elevated concentrations indicative of a leak. Monitoring ambient air identifies developing issues quickly before they escalate or contribute to unsafe gas accumulation in your facility.
Perform Bubble Testing to Pinpoint Leak Location
If a concerning leak is identified, bubble testing should be used to pinpoint the exact spot from which the gas is escaping. This simple and inexpensive method involves applying a specialized leak detection solution to connections, valves, fittings, and other components. Any bubbling that occurs precisely reveals the origin of the leak. This allows for quicker, more targeted repairs to be made.
Schedule Comprehensive Preventative Maintenance
Develop a schedule of thorough maintenance tasks to perform on all gas systems and equipment, including lubricating valves and fittings, recalibrating gas detectors, inspecting tubing and hose connectors, changing air filters, cleaning surfaces, and more. Follow all manufacturer recommendations for maintenance frequency and procedures. Proper preventative maintenance significantly reduces equipment failure risks over time.
Train Employees Extensively on Leak Prevention
Education and training are essential for prevention. Ensure all employees fully understand leak risks, equipment operation, inspection procedures, and emergency response steps. Emphasize that prevention is everyone’s responsibility. Provide clear guidance on how employees can proactively address hazards like improper equipment use that could lead to leaks. Focused training keeps leak diligence at the forefront of the mind.
Implement Redundancy and Fail-Safes
For critical gas supply systems, build in redundancy and fail-safes as an extra preventative line of defense. This may involve installing backup supply valves and regulators that activate if primary equipment fails. Automatic shut-off valves can also isolate leaks quickly. These measures provide additional protection if leaks develop despite other prevention efforts.
Detecting and preventing industrial gas leaks requires diligence, expertise, and the right equipment. Implementing these tips safeguards your facility, people, and bottom line. Contact Highmark Analytics today to evaluate your gas leak risks. Our team can conduct professional on-site assessments and recommend solutions tailored to your exact needs. Investing in safety now prevents significant problems in the future.
