The number of workplace injuries remains nearly unchanged year-over-year, with more than 2 million nonfatal workplace injuries and illnesses reported by provide industry employees in 2019.^[i] And up to 90% of workplace injuries can be attributed to human error.

While PPE has not traditionally had the technological capabilities to help prevent worker injury due to human error, the latest safety innovations, such as gas detection wearables, can help provide the visibility and data-driven insights to help your organization create an adaptable, proactive safety program and establish a culture of behaviour-based safety. Connected, wearable technology is leading the way for gas detection programs to evolve and enhance both their approach to worker safety and their approach to record-keeping, compliance, and fleet management.

But transforming your organisation to a connected program does not happen overnight. The first step is understanding the benefits of wearable technology and how a connected program can work for your organisation.

To start, what is a gas detection wearable? What are the benefits of connected safety technology? Here are answers to those top questions:

1. What is a gas detection wearable?

A gas detection wearable is designed to be worn by each individual worker, on his/her person, while on the jobsite. With a wearable detector that can simply clip directly on to apparel or other PPE, such as a fall harness, lone workers can be monitored in real-time to help provide critical data points about on-site workers to off-site safety managers, including emergency monitoring.

A wearable device can be a useful way to monitor workers’ safety, location, and behaviors; however, it may not always be enough to help build a proactive, adaptable gas detection safety program over time.

But a wearable gas detector that comes with automatic connectivity can be much more impactful in terms of driving transformation, efficiency, and reaching long-term safety and productivity goals of a gas detection program.

2. What does the term “connected” mean for gas detection hardware?

The term “connected” not only means a connected device – one that comes with out-of-the-box, cutting-edge cellular connectivity through leading national networks – but also a comprehensive solution inclusive of hardware software. It’s not necessarily enough to simply have cellular connectivity; hardware should also be connected to software, so that connectivity can provide the real-time data and insights to help drive adaptable, proactive safety programs.

This connectivity transforms hardware from traditional PPE to a technology-based, future-forward solution.  Successful integration of this advanced technology requires that not only are devices smarter and capable of providing visibility and insights to help curb risk, boost productivity, and simplify compliance, but also that they continue to perform with the durability and functionality to maintain their first and foremost mission of helping to protect the worker. As a wearable device, the detector should maintain the IP-rating, sensor technology, and battery life expected of today’s most durable portable gas detectors.

A wearable device that comes with automatic connectivity right out-of-the-box allows for quick and seamless implementation, no IT required.

3. How can wearable, connected technology help improve worker safety?

The most common industries for lone workers include oil and gas, telecommunications, utilities, construction, and industrial contractors. With wearable devices, safety managers can help ensure these lone workers are not completely alone. By digitally assigning a wearable device to individual workers at the start of each shift, safety managers can gain insight into key individual worker data including:

• Compliance of device use and faulty safety behaviours, including turning off an instrument or changing settings
• Workers’ locations, gas readings, and alarms
• Safety behaviours in the field, and whether new training specific to individuals is needed

A connected work program for gas detection can provide the visibility that is needed to manage large teams of workers and help establish a behaviour-based culture of safety. With real-time visibility of lone workers, safety managers can help make sure those workers are protected, with instant alerts. And  connected hardware and software solutions can provide real-time data such as worker location and how the detector is being used by each worker – which can all help inform safety training to both drive worker safety day-to-day and enhance an organisation’s safety culture over time.

4. How can wearable technology improve worksite safety?

It can be difficult to difficult to manage assets across different worksites and keep remote teams safe and productive. Connecting worksites with wearable, connected technology gives safety managers visibility into:

• Teams and assets, including worker position and activities and which devices require maintenance
• External and environmental factors, such as temperature or humidity
• Equipment status, maintenance, and asset management information across all worksite locations
• Centralized reports and data logs for automated compliance
• Intelligent mapping and zone segmentation, automated digital follow-ups, alarm sharing, and heatmapping to help drive operation-wide safety

With notifications available on both desktop and mobile devices, safety managers can get alerts when alarm exposure or SOS event occurs. Other details such as GPS location, gas readings, and compliance data are readily available within these immediate notifications provides safety managers with the visibility needed to manage safety and productivity across multiple worksites at once, all from remote, off-site locations.

5. How can wearable technology improve compliance and accountability across an organization?

Since a non-compliant detector can lead to potentially disastrous outcomes, it’s essential to ensure that every device is optimised. In other words, every device operates and protects the worker as it should. Technology not only makes this possible, it also makes it seamless. Advanced features that wearable technologies for gas detection should include are:

• Automatic bump tests and calibration when devices need it
• Visual indicators with green, yellow, and red lights representing “compliant,” “non-compliant,” and “in alarm,” respectively
• Device lock out to ensure that non-compliant devices are not inadvertently used
• Real-time historical data into specific workers

6. Can wearable devices help improve compliance and overall workflows?

Connected wearable devices allow you to connect workflows across your organization by providing insight into compliance and productivity issues. This information, coupled with connected cloud-based software, can allow you to:

• Automate compliance and help to reduce false alarms, remove asset-related risks, and lower the cost of downtime
• Determine if instruments have been configured correctly and are compliant in testing and while in use
• Create comprehensive reports in an industry standard format

7. What type of investment should an organization anticipate for implementing new wearable and connected technology across their workers and worksites?

With the latest technology, often comes newer business models to help drive your organizations’ transformation to a connected safety program. Subscription models that include both detector hardware and software options can help enable faster implementation, along with increased warranty coverage and ongoing software and firmware upgrades.

The right partner can help support your organisation’s connected safety journey with the right solution to fit your needs, from the number of wearables to various software options and features capabilities, giving you flexibility.

A seamlessly integrated solution of connected wearables and cloud-based software can provide visibility of your workers, worksite, and workflows that can make all the difference and help organizations drive a proactive safety culture over time.

Find out more about the latest innovations in connected gas detection wearables here.

Teledyne Gas and Flame Detection, a global leader in gas and flame detection solutions, is pleased to announce the launch of its new website, featuring updated informational content and a user-friendly interface.

The website is designed to provide an enhanced experience, including improved accessibility and mobile compatibility. It introduces new content on a range of gases, including H2 , CO, O2 , NH3 and more, helping users understand the potential risks associated with each gas and how to detect them. In addition, the site includes detailed information on the company's range of gas and flame detection products, such as detectors, controllers and alarms, making it easy for users to find the right product or service for their specific needs. The new website is designed with a responsive layout, ensuring that it looks and functions seamlessly on all devices, including desktops, laptops, tablets, and smartphones. Moreover, it is further improved with intuitive filtering options, allowing users to easily find the products they need without wasting time scrolling through irrelevant items.

We are thrilled to launch our website, providing our customers with efficient navigation. With proven reputations for quality and reliability, our dedication to safety now goes further.” said Marion Defasques, Global Digital Communication Developer of Teledyne Gas and Flame Detection. “With our updated comprehensive content and smart design, we are confident that our users will find the information they need quickly and easily, creating a more pleasant and productive browsing experience.” Visit Teledyne Gas and Flame Detection's new website to learn more about gas and flame detection solutions, and to take advantage of informational content and intuitive filtering options

Gas Detection Systems - Flame and gas detector, hazardous gas detection monitors | Teledyne GFD (teledynegasandflamedetection.com)

Levels of uncertainty in gas measurements can be increased, for example, by calibration gases that offer poor levels of accuracy. For this reason, Signal Group manufactures gas handling and calibration equipment as well as gas analysers. “The linearity check is particularly important,” explains Managing Director James Clements. “Our Model 821S Gas Divider, for example, has been tested independently against our main competitor globally, and found to be dramatically superior.”

Conducted in North Carolina, USA, the trial found the slope accuracy for the Signal 821S to be just 0.25% for a NO/N2 gas mixture, whereas the competitor gas divider offered 1.6% slope accuracy. Similarly, for a SO2/N2 mixture Signal’s slope accuracy was 0.74% and the competitor’s was a disappointing 2.5%.

“Sources of uncertainty are incremental,” Jamesexplains, “so it makes no sense to introduce extra error unnecessarily, which is why the 821S Gas Divider is popular with both our customers and with other gas analyser manufacturers.”

The European standard EN14181 describes the quality assurance procedures for Automated Measurement Systems (AMS) installed to measure emissions to air. Under this standard, an analyser’slinearity must be checked using five different reference concentrations, including zero. The reference concentrations should be approximately 20%, 40%, 60% and 80% of the range of two times the emission limit, and the test concentrations should be applied in a randomised sequence.

It is common practice to employ a gas divider to create the different reference concentrations, however, it is of course also necessary to be able to validate the gas divider. To protect accuracy and reliability, the Signal Group Model 821S Gas Divider does not use mass flow controllers. A manifold block with ten identical capillaries and a precision pressure balance regulatorensure the high levels of accuracy demonstrated in the USA trial.

The procedurefor checking the accuracy of the 821S Gas Divider is simple. Users connect the zero and calibration gas to the opposite connections and repeat the test, and if the gas divider is operating correctly, the gas analyser will show exactly the same readings.

Summarising, James Clements says: “Bottles of calibration gas have a fixed ‘use-by’ date and can be expensive to purchase and store, so it makes sense to employ a gas divider to conduct multi-point calibrations. However, purchased calibration gas itself incurs a level of uncertainty, so we designed the 821S Gas Divider to minimise increases in uncertainty, and I am grateful to the researchers in North Carolina for highlighting this technical superiority.”

The topic of “explosion safety” is widespread for plant operators and OEM´s when it comes to handling or transporting combustible dusts. Despite the common assumption that an increased risk of explosion only exists for gases, enormous forces can also be released by explosive dust- / air mixtures.

To help minimize the risk of explosions when handing combustible dusts, it is important to understand the requirements for an explosion and the respective dust safety characteristics, which are described below. The following picture shows the explosion pentagon which must be taken into account.

The following conditions must exist for an explosion to occur within a production facility or machine:

Fig. 1: Explosion pentagon

If any one of the afore mentioned prerequisites is eliminated, explosion prevention has intrinsically been practiced. However, if this is not possible at all times and in all operating states, explosion hazards will still be present. In that case, it is necessary to divide any potentially explosive atmospheres into zones and systematically apply safety measures.

Drying processes in particular are used in many industries to produce material, for easier storage, more efficient transport and a longer shelf life. However, the combination of moisture extraction and high temperatures creates an increased risk of both fire and explosions.

If fires and/or explosions occur in drying plants, which are usually very large, the situation is not only extremely dangerous for the machines and the business, but especially for the employees on site.

Operators of spray dryers must combat a particular type of ignition source – namely smouldering nests that can lead to spontaneous combustion if the material undergoes excessive caking. Caking occurs due to sub-optimal drying of the material and its initially high moisture content. The caked material is then insulated against the surrounding air by a build-up of moist material. The high temperatures ensure that the caked material is continuously heated until a biological reaction takes place involving protein, carbohydrates and water – known as the Maillard reaction. The Maillard reaction generates additional heat that cannot be dissipated due to the insulating layer of caked material. This exothermic process continues to accelerate until spontaneous combustion finally occurs.

Caking of this kind can build up both on the nozzles and the inner wall of the spray dryers. If the nozzle malfunctions, droplets may drip into the fluid bed and cause further clumping. If a smouldering nest is able to form, this can ignite the explosive atmosphere inside the dryer or the downstream machinery.

How can such conditions, which are frequently encountered in practice, be prevented?

Everything starts with the human factor, i.e. properly trained personnel for the respective processes. Optimal process control is also required to avoid caking. But without precise and reliable information/measurements, this is virtually impossible, even for specialists. Nowadays, humidity and one of the by-products of spontaneous combustion at early stages – carbon monoxide (CO) – are used as indicators to ensure a smooth and thus safe process. However, the fact that combined measurement systems cannot clearly distinguish between these two indicators is problematic and can result in inaccurate measurements.

The REMBE CO.Pilot – Synergistic CO and Humidity Measurement

The REMBE CO.Pilot autonomously performs continuous comparison of measured gas data with a synchronized database of stored reference gases that serve as "fingerprints" of the selected process and combustion gases. This allows the possibility to perform a real-time check to continuously verify the measurement accuracy as a self-calibration. At the same time, the real-time fingerprint analysis eliminates the cross-sensitivity to other gases in the measurement spectrum which is problematic with other commercial gas analysers.

To ensure a reliable measurement of the operating status, samples are sucked in from all of the dryer's relevant supply and exhaust air ducts under very high vacuum. REMBE calculates the delta CO value on the basis of the absolute values measured at the individual measuring points. This value is the mathematical difference between the CO content of the extract air and the CO content of the supply air. Thus, only events that actually occur in the respective process are detected. External factors that may disturb the measurement process can thus be ignored.

A proprietary evaluation algorithm, the REMBE Flow Algorithm, (RFA), enables the measured supply and exhaust gas stream values to be compared in real time. As a result, the REMBE CO.Pilot is the first system on the market that makes it possible to adjust the individual alarm limits and gas residence times for the individual measuring points in the dryer's various air throughputs without any delays. The ratios of the different supply air channels and the  associated predicted process gas streams are analysed via the software and calculated to determine an upset condition in the incipient stage.

Thus, if an increased carbon monoxide concentration is detected due to spontaneous combustion during the process, countermeasures can be initiated immediately.

But what does this mean in detail?

This special sampling process eliminates the need for costly and error-prone gas treatment, thus ensuring that the CO.Pilot is less susceptible to faults and requires less maintenance. Furthermore, this measurement method can make recurring calibrations unnecessary. Due to the precise measurement technology and the reproducible results, false alarms and downtimes can also be avoided. In combination with moisture measurements, the entire drying process can be optimally controlled, significantly increasing the energy efficiency of the system.

Fig. 2: REMBE CO.Pilot

Contact REMBE^® Inc. at This email address is being protected from spambots. You need JavaScript enabled to view it. / www.rembe.us .

Explosion isolation is essential for comprehensive explosion protection. Without isolation, an explosion safety concept is not only incomplete, but is also a waste of money for operators as:

In almost every production facility, individual plant components are interconnected by means of pipelines. The purpose of explosion isolation is to seal these pipelines in the event of an explosion to prevent the propagation of pressure and flames, thereby protecting the adjacent plant components. Precompression and flame jet ignition increase the severity of the explosion in the connected vessels. This leads to secondary explosions that can cause even more catastrophic damage.

Isolation systems prevent an explosion from propagating, thereby reducing the effects of the explosion to a minimum. Adjacent system components are optimally protected.

A distinction is made between active and passive isolation systems:

Active systems use sensors or detectors to detect an explosion as it occurs by registering the rising pressure or flames as they form and activate the associated isolation device, e.g. a quench valve.

Due to their structural design, passive isolation systems react purely mechanically to a propagation or loss of pressure. The latter also applies to explosion isolation flap valve. They are kept open during normal mode by means of the currents present in the pipeline. In the event of an explosion, the valve closes due to the propagating pressure front, effectively preventing the further propagation of pressure and flames.

www.rembe.de

As the inventor of flameless explosion venting, REMBE is once again challenging the status quo with the new Q-Box R3leaf, the world's first sustainable device for flameless explosion venting.

After years of systematic development, testing and successful approval tests, REMBE is convinced that it has contributed to more than just an improvement in flameless explosion venting technology. Instead, the aim is to set a good example and send a clear signal that everyone can reduce the carbon footprint in our industry. 

Fig. 1: The Q-Box R3leaf as the first sustainable flameless explosion venting device

During development of the Q-Box R3leaf the focus was on sustainability and the central question: Where can the status quo be further challenged?  

The development of the Q-Box R3leaf expands REMBE's line of flameless explosion venting devices with a product optimised in terms of both effectiveness and sustainability.  

Thanks to the selection of materials, the geometry of components and appropriate joining processes, it was possible to significantly increase the packaging density, avoid the need for emission-intensive joining and coating processes, and at the same time significantly improve the effectiveness of internal and international logistics processes. These optimisations affect the entire supply chain of the Q-Box R3leaf and thus ensure reduced CO₂ emissions.

Thanks to continuous development, it was possible to significantly increase the venting efficiency of the Q-Box R3leaf, allowing plant operators to reduce the number of flameless explosion venting devices required on their plant.

How does an explosion occur?

The topic of “explosion protection” is omnipresent for plant operators and machine manufacturers when it comes to handling or transporting flammable and explosive dusts. Contrary to the widespread assumption, the risk of explosion extends beyond gases, as flammable dusts can release enormous forces.

The following conditions, also known as fire triangle or dust explosion pentagon, must exist for an explosion to occur within a production facility or machine:

Fig. 2: Dust explosion pentagon

If any of the aforementioned conditions are eliminated, explosion protection has essentially been practised. However, if this is not possible at all times and in all operating states, explosion hazards persist. This necessitates categorizing explosion-prone areas into zones and systematically installing protective measures accordingly.

What is flameless explosion venting? 

Flameless explosion venting devices are primarily used to protect vessels or plants against the main effects of explosions, flames and pressure, which would be released unhindered into the environment if conventional explosion venting was used. To put it simply, they consist of two elements: the explosion venting device, such as an explosion vent and a downstream flame extinguishing element. This decreases the explosive pressure to a level that is harmless for the protected plant, and at the same time reduces the temperature of the combustion gases to a harmless level.

Flameless explosion venting devices are used wherever safe pressure relief in the event of an explosion is not permitted due to the potential proximity to people, other plants or objects.

www.rembe.com

Meeting safety and process requirements at the same time is sometimes a challenge, especially in the pharmaceutical industry. Dust-handling equipment has to be equipped with explosion protective systems, which must also comply with all hygiene and sanitary requirements in production. The solution: Vent panels that can be used to produce hygienically sensitive powders.

The EGV HYP vent panel is an economical solution to the problem described, according to the strict criteria of the EHEDG (European Hygienic Engineering & Design Group). Specially designed for hygienically demanding processes, it protects the vessel in the event of an explosion by releasing flame and pressure. The smooth surface with the patented, full-flat, chamfered gasket system prevents deposits during the production process and during the cleaning of the system and thereby cross-contamination between batch processes. With the new, contrasting blue color of the seal, it is also easy to see if the seal is damaged and/or a mounting failure has happened.

The EGV HYP can be used without hesitation in critical systems such as spray dryers with / without CIP cleaning, fluid bed dryers and mixers and therefore offers a cost-effective safety solution according to the requirements of hygienic design.

Fig.1: Certified in accordance with EHEDG: EGV HYP with patented, bevelled sealing concept for absolute hygiene. 

www.rembe.de